Académique Documents
Professionnel Documents
Culture Documents
Manual
for Installation, Function,
and Initial Start-Up
Truck
Edition: 2007-10
ZF-AS Tronic
Preface
To avoid
Writing of customer specification for the transmission system by vehicle manufacturer and ZF,
Documentation by ZF,
Initial installation,
NOTE
If the specifications noted in this technical manual
are not observed or if parts which are not approved
by ZF or are not genuine ZF parts are used, this may
result in damage as well as functional limitations for
which ZF shall assume no responsibility.
ZF-AS Tronic
List of Chapters
Function Description
Installation
Annex
ZF-AS Tronic
Table of Contents
Applicable Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
15
1.1
General
......................................................................
1-3
1.2
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
2.1
System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2.2
2-4
2.2.1
Description of Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
2.2.2
2-6
2.2.3
2-7
2.2.4
2-8
2.2.5
2-9
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10
2.2.11
2.2.12
2.2.13
2.3
2.4
2.3.2
2.4.1.1
2.4.1.2
ZF-AS Tronic
2.5
Table of Contents
2.4.2
2.4.2.1
2.4.2.2
2.4.3
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.5.1
Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.5.1.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.5.1.2
2.5.1.3
2.5.1.4
2.5.1.5
2.5.1.6
2.5.1.7
2.5.1.8
2.5.2
PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2.5.2.1
2.5.2.2
2.5.2.3
2.5.2.4
Retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Description of Function
3.1
Basic Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
3.1.1
3-4
3.1.2
3-4
3.1.2.1
3-4
3.1.2.2
3-4
3.1.2.3
Shifting to Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4
3.1.3
Setting Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3.1.4
3-7
3.1.4.1
Upshifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
3.1.4.2
Downshifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
ZF-AS Tronic
3.2
3.3
Table of Contents
3.1.5
Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
3.1.6
3.1.6.1
3.1.6.2
3.1.7
3.1.7.1
3.1.7.2
3.1.8
3.2.2
3.2.3
3.2.4
Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.4
3.5
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.5.1
3.5.2
3.5.3
Installation
4.1
4-5
4.1.1
4-5
4.1.2
.......................
4-5
4.1.3
Input Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
4.1.4
4-6
ZF-AS Tronic
Table of Contents
4.1.5
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6
4.1.6
4-8
4.1.7
Engine Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9
4.1.8
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.1.9
4.1.10
4.1.11
4.2
4.3
4.1.12
4.1.13
4.1.14
4.1.15
4.1.16
Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.1.17
4.1.18
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
ZF-AS Tronic
4.4
Electrics
Table of Contents
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.4.1
4.4.2
4.4.2.1
4.4.2.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.7.1
4.4.7.2
4.4.8
4.4.9
4.5
Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.6
Auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.7
4.6.1
ZF-Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.6.2
4.6.3
4.6.4
4.6.5
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4.7.2
4.7.3
4.7.4
4.7.5
4.7.6
4.7.7
10
ZF-AS Tronic
4.8
Table of Contents
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
4.8.1.1
4.8.1.2
4.8.1.3
Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
4.8.1.3.1 Maneuvering via the accelerator pedal with rotary switch in D or R position . . . . . . . . 4-47
4.8.1.3.2 Maneuvering acc. to rotary switch position DM or RM . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
4.8.1.4
4.8.1.5
4.8.1.6
4.8.1.7
4.8.1.8
4.8.1.9
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4.9
4.8.2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4.8.2.1
4.8.2.2
4.8.3
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4.9.2
ZF Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4.9.3
4.9.4
11
ZF-AS Tronic
Table of Contents
Annex
5.1
5-3
5.2
AS Transmission Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4
5.2.1
5-4
5.2.2
5-5
5.2.3
5-5
Attached Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6
5.3
12
ZF-AS Tronic
List of Documents
warranty cover granted by ZF cannot otherwise be
assured.
The documents attached to the technical manual are
provided for information only. Please contact your
personal contact in the Technical Sales department
if you need binding drawings for installation investigations etc.
Type of document
Techn. information
Form
Form
Standard
Standard
Standard
Specification
CD-Rom
Diskette
TE-ML 02
List of Lubricants
Type sheet
TKI
Signal specification
Specification
Clutch
Type sheet
TKI
Transmission actuator
TKI
Vehicle wiring
Installation drawing
TKI (E-Module 2)
Technical manual
ZF-Intarder
CD-Rom
ZF-Intarder
Installation manual
PTOs
---
Type sheet
Testman Pro
13
ZF-AS Tronic
List of Abbreviations
List of Abbreviations
ABS
ASC
Anti-Slip Control
BA
Operating Instructions
Bu
Bush contact
CAN
DBV
E-box
Electronics box
E-module
Electronic module
EBZ
Installation drawing
ECU
EDC
EMC
Electro-magnetic compatibility
EOL programming
End-of-line programming
FMEA
GP
GV
HF line
IT
Intarder
JPT
K line
Communication line
KWP
MV
Solenoid valve
PF
Product family
PTO
Rear axle
Hydraulic connection
RSV
Non-return valve
ST MNL
STVZO
Highway code
SW
Software
TCU
Term. 15
Terminal 15 (switched to +)
Term. 30
Terminal 30
TKI
WS
Travel sensor
14
ZF-AS Tronic
Index
Date of issue
1999-12
2000-09
Chapter
2
4
Initiator
Remark
LPE2-B
Complete revision
LPE2-B
5
c
2002-09
LPE2-B
Contents revised:
List of documents , 2.2 - 2.5, 3.1 - 3.5, 4.1.5,
4.1.8, 4.1.9, 4.1.17, 4.1.18, 4.2, 4.4.1, 4.4.5, 4.4.6,
4.4.7, 4.5, 4.7.5, 4.7.7
Editorial revision:
1, 2.1, 4.1.1, 4.1.2, 4.1.4, 4.1.6, 4.1.10, 4.1.16, 4.3, 4.4.8,
4.7.6, 4.1.10, 4.1.16, 4.3, 4.4.8, 4.7.6, 4.8.1, 4.9.1
Added:
List of abbreviations, 5.1, 5.2
Replaced by:
2002-10
LPE2-B
Contents revised:
2.2.9, 2.2.11, 3.2.4, 4.2, 4.2.5, 4.7.4, 5.1, 5.2.2
Editorial revision:
Copyright, Preface, 3.1.3, 4.4.6
Added:
Replaced by:
2003-08
LPE2-A
Contents revised:
2.2, 2.5, 3.1.6, 3.1.7, 4.1 - 4.5, 5.1, 5.2
Editorial revision: 1, 2.4.1, 3.5, 4.7, 4.9
Added: 2.4.2, 4.8.1, 4.8.2
Replaced by:
2005-04
LPE2-A
Contents revised:
2.2.4 - 2.2.16, 2.4.2.1, 2.4.4, 2.5.2, 3.2, 4.1.1, 4.1.6, 4.1.8,
4.1.15, 4.2.4, 4.3.1, 4.3.2, 4.3.7, 4.4.7, 4.5, 4.6.5, 4.7.1,
4.9.3, 5.2
Editorial revision:
3.1.3 - 3.1.7, 3.3.2, 3.5.2, 4.1.5, 4.1.9, 4.1.10, 4.1.16, 4.3.6,
4.4.4, 4.7.7
Added: 1.2, 2.2.3, 2.4.2.2, 2.4.3, 4.3.8, Fig. 2.3
Replaced by:
2006-05
LPE2-A
Contents revised:
1, 2.1, 2.2.3 - 2.2.16, 2.4.1 - 2.4.2.2, 3.1, 3.1.7, 3.5.2, 4.1.8,
4.1.16, 4.2.4, 4.3.2, 4.3.4, 4.4.1, 4.4.6, 4.4.7.2, 4.7.4, 4.8.1,
4.8.1.1, 4.8.1.3, 4.8.1.5 - 4.8.1.7, 4.8.1.11, 5.2.1, 5.2.3, 5.3
Editorial revision:
3.3.2, 4.1.10
Added: 4.1.11.1, 4.1.11.2, 4.8.1.3.1, 4.8.1.3.2
Replaced by:
1
2
3
4
5
15
ZF-AS Tronic
Index
Date of issue
Chapter
2007-09
2
3
4
Initiator
Remark
Contents revised:
2.2.4 - 2.2.13, 2.4.1.1, 3.1.3, 3.1.5, 3.1.7, 3.1.7.1, 3.1.7.2,
3.2.2, 4.1.7, 4.1.9, 4.2.4, 4.2.5, 4.3.1, 4.7.6, 4.9.4, 5.3
Editorial revision:
Bus-specific descriptions were removed as SB is preparing
its own THB (Technical Manual). Standardization of
descriptions: TCU, ECU, EST and System CAN, Vehicle CAN,
and Vehicle System CAN
Added:
Replaced by:
16
ZF-AS Tronic
Table of Contents
1.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1.2
Interfaces
1-4
.................................................
1-1
1-2
ZF-AS Tronic
1
Brief Description
ZF-AS Tronic
027530
1.1
General
The driver has the opportunity to drive the vehicle
in both semi-automatic mode and fully automatic
mode. When in semi-automatic mode, manual shifting is simplified through the use of a range selector.
1-3
ZF-AS Tronic
1.2
Brief Description
Interfaces
6 9 13 2
4 15 14
10
12
16
11
17
024350
1-4
ZF-AS Tronic
Brief Description
Key
Item
Parameter
Link / Resp. HB
Mechanical interface
1
Engine
Geometry of SAE 1
Chap. 4.1.7
Torque arm
Chap. 4.1.8
Chap. 4.1.11 / 12
Temperature
Chap.2 ff.
Transmission suspension
(optional)
Output
Rotational irregularity
Chap. 4.1.10
Nout max
2.2.3 ff.
Input shaft
Clutch
Chap. 4.1.8
Rotational irregularity
Chap. 4.1
Pilot bearing
Chap. 4.1.7
Chap. 4.1.6
Friction characteristics
Chap. 4.1.5
Inertia torque
Chap. 4.1.5
Geometry
Collision
Chap. 4.1.6
Electronic interface
6
6a
Transmission actuator
Connector on vehicle
Wiring
Chap. 4.1.17 / 18
Chap. 4.1.16
Accessibility
Engine messages
ABS/EBS messages
Onboard computer /
PTO messages
Speedo messages
Display messages
Diagnosis messages
Diagnosis capability
Chap. 4.4.8
Chap. 4.4.4
Agreement
with ZF
Interface / Application /
testing
6c
Diagnosis messages
Diagnosis capability
Neutral switch
Nominal voltage 24 V
Speedometer
Tachograph
Sensor selection
Chap. 4.4.7.2
Transmission actuator
Pressure
Chap. 4.5
Clutch actuator
Air quality
Pneumatic interface
9
10
Additional interface
11
Heat exchanger
optional
Chap. 4.2.4
Bypass valve
12
13
ZF PTO (optional)
Chap. 2.5.2
Connector on vehicle
Chap. 2.4.1.2 /
Chap. 2.4.2.2
Chap. 4.1.17 /
Chap. 4.5
Transmission bleeding
Chap. 4.3.7
Ambient condition
14
Oil
15
Corrosion protection
Chap. 4.7.3
16
Chap. 4.1.15
17
Temperature
1-5
1-6
ZF-AS Tronic
Table of Contents
2.1
System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10
2.2.11
2.2.12
2.2.13
2-4
2-4
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
2-15
2-16
2-17
2.3
2.3.1
2.3.2
2.4
2.4.1
Peripheral Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF Selector Lever With Integrated E-Module and
Additional ZF Extension Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF selector lever with integrated E-module . . . . . . . . . . . . . . . . . . . . . . . . .
ZF Extension Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF Range Selector Module + ZF Extension Module . . . . . . . . . . . . . . . . . . .
ZF Range Selector Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF Extension Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1.1
2.4.1.2
2.4.2
2.4.2.1
2.4.2.2
2.4.3
2-1
2-20
2-20
2-20
2-22
2-23
2-23
2-23
2-24
ZF-AS Tronic
Table of Contents
2.5
2.5.1
2.5.1.1
2.5.1.2
2.5.1.3
2.5.1.4
2.5.1.5
2.5.1.6
2.5.1.7
2.5.1.8
2.5.2
2.5.2.1
2.5.2.2
2.5.2.3
2.5.2.4
Auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Grade and Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedo Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch-Dependent PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Driven PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine-Dependent PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
2-27
2-27
2-27
2-27
2-27
2-27
2-27
2-28
2-28
2-28
2-28
2-28
2-29
2-29
2-29
ZF-AS Tronic
2.1
System Design
components and instead uses the vehicles systems
such as engine electronics with accelerator pedal (6)
and brake pedal (7), electronic brake system with
wheel speed sensors etc.
The transmission system consists of the transmission (1) and the components needed to automate
the system. The transmission actuator (2) and clutch
actuator (3) components are integrated in the
transmission. The peripheral components, i.e. the
range selector (4), rotary switch (9), display (5), and
ZF extension module (8) should also be installed in
the vehicle.
8
1
4
D
DM
R
RM
6
7
1
2
3
4
5
Transmission
Transmission actuator
Clutch actuator
Range selector
Display
6
7
8
9
Accelerator
Brake pedal
ZF extension module
Rotary switch
027513
2-3
ZF-AS Tronic
2.2
2-4
ZF-AS Tronic
Transmission
brake Splitter
group
3 2
4-speed
transmission
Range-change
group
014867
Fig. 2.2
Example: ZF-AS Tronic, 16-speed with 2 countershafts
Splittergroup
3-speed
transmission
K1
K2
Reverse
Range-change
group
Transmission
brake
024459_en
Fig. 2.3
Example: ZF-AS Tronic mid with one countershaft
1328 765 101 - 2007-10
2-5
ZF-AS Tronic
g
Gpaened
1166-s
GV
3/4
1/2
GP
ged
sGpaen
1212-
GV
2/3
1
2
3
4
5
1/R
GP
019489 / 019490
Fig. 2.4
Transmission actuator
Shift cylinder for splitter group
Shift cylinder for main transmission
Shift cylinder for the range change group
Selector cylinder for main transmission
2-6
2-7
12
AS
200
400
600
800
1000
1200
1400
1600
1800
2000
10
10
TO
12
AS
AS
TD
12
0
01
0
21
TO
12
AS
AS
TD
12
0
22
AS
TO
12
0
42
1
AS
TD
12
0
42
1
0
62
12
TO
* under development
Directdrive
2400
2200
Overdrive
Key
AS
900 mm
Installation length
16
AS
TD
12
30
Product
Family 2 2
Produktfamilie
2600
2800
3000
3200
840 mm
Installation length
Product
Family 11
Produktfamilie
ZF - AS Tronic mid
1 countershaft
ZF
- AS Tronic mid
AS
TO
12
0
93
AS
TD
12
0
93
21
AS
TO
12
30
AS
TD
12
0
13
12
0
33
AS
TO
910 mm
Installation length
Product Family 3
12-speed
23
AS
TD
12
30
0
53
TO
16
AS
2 countershafts
16
AS
TD
2
O
63
TO
12
953 mm
Installation
length
AS
Product Family 3
16-speed
0
23
ZF - AS Tronic
12
0
14
AS
TD
2
12
0
34
AS
TD
2
AS
TO
12
0
54
AS
TD
12
40
25
40
27
TO
12
953 mm
Installation length
Product Family 4
12-speed
AS
*
AS
TO
12
40
29
0
14
TO
028962_en
ZF-AS Tronic
Transmission System and its Components
ZF-AS Tronic
Input speed:
Oil volume:
840 mm
Weight:
183 kg**
12.83 - 1.0
13.07 - 10.56
12
Forwards
Reverse
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
1) Higher torque upon request.
Powerflow diagram
KI
Gear
1.
Ratio
i
12.834
Inertia torque 1)
kgm2
10.369
0.062
0.086
0.067
0.093
0.078
0.109
0.083
0.118
0.120
0.174
10
0.205
11
1.291
3.
8.029
1.238
4.
6.487
1.253
5.
5.176
1.238
6.
4.182
1.363
7.
3.069
1.238
8.
2.480
1.291
9.
1.920
1.238
10.
1.551
1.253
11.
1.238
1.000
R1
13.072
0.304
10.561
0.086
0.059
0.081
PL
PTO
R1
0.062
1.238
R2
N K1
N K2
12
1.238
12.
2 1
Gear
1.238
2.
3
KII
R2
PTO-K1
PTO-K2
019425
2-8
ZF-AS Tronic
Input speed:
Oil volume:
840 mm
Weight:
183 kg**
12
Forwards
Reverse
10.37 - 0.81
10.56 - 8.58
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
1) Higher torque upon request.
12-speed / overdrive
Powerflow diagram
3
KI
Gear
1.
Ratio
i
10.369
Inertia torque 1)
kgm2
8.428
0.084
0.108
0.091
0.118
0.107
0.143
1.299
3.
6.487
1.230
4.
5.273
1.261
5.
4.182
1.230
6.
3.399
7.
2.480
8.
2.015
9.
1.551
10.
1.261
11.
1.000
12.
0.813
0.437
R1
10.561
0.084
R2
N K1
N K2
8.584
1.371
PL
PTO
0.116
1.230
0.156
1.299
0.172
1.230
10
0.241
11
1.261
0.302
12
1.230
R1
1.230
Gear
1.230
2.
KII
2 1
0.107
0.105
0.075
R2
PTO-K1
PTO-K2
019426
2-9
ZF-AS Tronic
Oil volume:
900 (910) mm
Weight:
201 kg**
12.83 - 1.0
13.07 - 10.56
12
Input speed:
Number of forward gears:
Ratio range:
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
1) Higher torque upon request.
Powerflow diagram
KI
Gear
1.
Ratio
i
12.834
Inertia torque 1)
kgm2
10.369
0.072
0.101
0.077
0.108
0.089
0.126
0.094
0.134
0.132
0.193
10
0.221
11
1.291
3.
8.029
1.238
4.
6.487
1.259
5.
5.176
1.238
6.
4.182
1.363
7.
3.069
1.238
8.
2.480
1.291
9.
1.920
1.238
10.
1.551
1.253
11.
1.238
1.238
12.
1.000
R1
13.072
0.329
0.072
1.238
R2
N K1
N K2
10.561
0.100
0.069
0.096
2 1
PL
PTO
Gear
1.238
2.
3
KII
12
R1
R2
PTO-K1
PTO-K2
019425
2-10
ZF-AS Tronic
Oil volume:
900 (910) mm
Weight:
201 kg**
12
Input speed:
Number of forward gears:
Ratio range:
10.37 - 0.81
10.56 - 8.58
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
1) Higher torque upon request.
12-speed / overdrive
Powerflow diagram
3
KI
Gear
1.
Ratio
i
10.369
Inertia torque 1)
kgm2
8.428
0.098
0.127
0.106
0.138
0.123
0.165
0.131
0.177
1.299
3.
6.487
1.230
4.
5,273
1.261
5.
4.182
1.230
6.
3.399
7.
2.480
1.371
1.230
8.
2.015
9.
1.551
1.299
1.261
0.266
10
0.326
11
1.261
11.
1.000
12.
0.813
R1
10.561
0.473
R1
0.098
1.230
8.584
0.126
0.124
0.087
PTO
12
1.230
R2
N K1
N K2
PL
0.190
1.230
10.
Gear
1.230
2.
KII
2 1
R2
PTO-K1
PTO-K2
019426
2-11
ZF-AS Tronic
Oil volume:
approx. 12 liters
910 mm
Weight:
242 kg**
15.86 - 1.0
14.68 - 11.41
12
1 600 - 2 300 Nm
Input speed:
Number of forward gears:
Ratio range:
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, Intarder, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
Powerflow diagram
KI
KII
3
21
PTO
R
PL
Gear
1.
Ratio
i
15.858
Inertia torque 1)
kgm2
Gear
0.092
0.143
0.096
1.287
2.
12.326
1.289
3.
9.565
1.287
4.
7.435
0.150
1.266
5.
5.873
0.106
0.167
0.112
0.176
0.151
0.241
10
0.252
11
0.409
12
R1
1.287
6.
4.565
1.314
7.
3.474
1.287
8.
2.700
9.
2.095
10.
1.629
11.
1.287
12.
1.000
R1
14.683
R2
N K1
N K2
11.413
1.289
1.287
1.266
1.287
1.287
0.090
0.140
R2
PTO-K1
2-12
018742
ZF-AS Tronic
Output speed:
910 mm
Oil volume:
approx. 12 liters
12.33 - 0.78
11.41 - 8.88
Weight:
240 kg**
12
1 900 -2 500 Nm
Input speed:
Number of forward gears:
Ratio range:
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, Intarder, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
12-speed / overdrive
Powerflow diagram
KI
KII
3
21
PTO
PL
Gear
1.
Ratio
i
12.326
Inertia torque 1)
kgm2
Gear
0.118
0.186
0.123
0.195
0.137
0.218
0.155
0.247
0.225
0.362
10
0.406
11
0.662
12
1.285
2.
9.590
1.290
3.
7.435
1.285
4.
5.784
1.267
5.
4.565
1.285
6.
3.552
1.316
7.
2.700
1.285
8.
2.101
1.290
9.
1.629
1.285
10.
1.267
1.267
11.
1.000
1.285
12.
0.778
R1
11.413
R1
1.285
R2
N K1
N K2
8.880
0.181
0.115
R2
PTO-K1
2-13
018741
ZF-AS Tronic
Oil volume:
approx. 13 liters
953 mm
Weight:
255 kg**
17.03 - 1.0
15.77 - 13.07
16
2 200 Nm
Input speed:
Number of forward gears:
Ratio range:
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, Intarder, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
Powerflow diagram
KI
KII
4
32
1R
PTO
PL
Gear
1.
Ratio
i
17.029
Inertia torque 1)
kgm2
Gear
0.100
0.139
0.102
0.143
0.107
0.149
0.115
0.162
0.120
0.169
10
0.146
11
0.207
12
0.201
13
0.287
14
0.309
15
0.443
16
1.206
2.
14.120
1.227
3.
11.504
1.206
4.
9.539
1.213
5.
7.864
1.206
6.
6.521
1.184
7.
5.506
1.206
8.
4.565
1.224
9.
3.730
1.206
10.
3.093
1.227
11.
2.520
1.206
12.
2.089
1.213
13.
1.723
1.206
14.
1.428
1.184
15.
1.206
1.206
16.
1.00
R1
15.768
R2
N K1
N K2
13.074
R1
1.206
0.098
0.137
R2
PTO-K1
2-14
014282
ZF-AS Tronic
Output speed:
953 mm
Oil volume:
approx. 13 liters
14.12 - 0.83
13.07 - 10.81
Weight:
252 kg**
16
2 600 Nm
Input speed:
Number of forward gears:
Ratio range:
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, Intarder, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
16-speed / overdrive
Powerflow diagram
KI
KII
4
1R
PTO
PL
Gear
1.
Ratio
i
14.120
Inertia torque 1)
kgm2
Gear
0.123
0.174
0.126
0.178
0.133
0.188
0.145
0.206
0.152
0.217
10
0.191
11
0.272
12
0.270
13
0.389
14
0.427
15
0.617
16
1.209
2.
11.677
1.224
3.
9.539
1.209
4.
7.889
1.210
5.
6.521
1.209
6.
5.393
1.181
7.
4.565
1.209
8.
3.776
1.221
9.
3.093
1.209
10.
2.558
1.224
11.
2.089
1.209
12.
1.728
1.210
13.
1.428
1.209
14.
1.181
1.181
15.
1.000
1.209
16.
0.827
R1
13.074
R1
1.209
R2
N K1
N K2
10.812
R2
0.170
0.120
PTO-K1
2-15
014283
ZF-AS Tronic
Oil volume:
approx. 13 liters
953 mm
Weight:
256 kg**
15.86 - 1.0
14.68 - 11.38
12
2 100 - 2 500 Nm
Input speed:
Number of forward gears:
Ratio range:
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, Intarder, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
Powerflow diagram
KI
KII
3
21
PTO
R
PL
Gear
1.
Ratio
i
15.858
Inertia torque 1)
kgm2
Gear
0.100
0.158
0.104
0.163
0.112
0.177
0.127
0.202
0.177
0.286
10
0.306
11
0.501
12
R1
1.290
2.
12.292
1.285
3.
9.565
1.290
4.
7.414
1.259
5.
5.890
1.290
6.
4.565
1.314
7.
3.474
1.290
8.
2.693
1.285
9.
2.095
1.290
10.
1.624
11.
1.290
12.
1.000
R1
14.680
R2
N K1
N K2
11.380
1.259
1.290
1.287
0.099
0.155
R2
PTO-K1
2-16
018740
ZF-AS Tronic
Output speed:
953 mm
Oil volume:
approx. 13 liters
12.29 - 0.78
11.38 - 8.88
Weight:
252 kg**
12
2 500 - 2 700 Nm
Input speed:
Number of forward gears:
Ratio range:
* Approximate value: Depends on type of vehicle and vehicle data as well as the prevailing operating conditions.
** Without peripherals, oil fill, PTOs, Intarder, clutch, release fork, release shaft, release bearing, push rod, and clutch actuator.
Weight: Release fork, release shaft, release bearing, push rod, and clutch actuator approx. 10 kg.
12-speed / overdrive
Powerflow diagram
KI
KII
3
21
PTO
R
PL
Gear
1.
Ratio
i
12.292
Inertia torque 1)
kgm2
Gear
0.132
0.207
0.137
0.216
0.151
0.240
0.176
0.281
0.260
0.418
10
0.475
11
0.771
12
1.282
2.
9.590
1.293
3.
7.414
1.282
4.
5.784
1.267
5.
4.565
1.282
6.
3.562
1.323
7.
2.693
1.282
8.
2.101
1.294
9.
1.624
1.282
10.
1.267
1.267
11.
1.000
1.282
12.
0.780
R1
11.380
R1
1.285
R2
N K1
N K2
8.880
R2
0.202
0.129
PTO-K1
2-17
018743
ZF-AS Tronic
2.3
Transmission Components
Integrated
transmission electronics
Compressed air
connection and
pressure relief valve
Valves
Shifting
Selecting
Transmission
brake
Splitter group
Range-change
group
Central air
Connector on
transmission
Connector on
vehicle
Sensors
Travel
Temperature
Speed
Pressure
Shift cylinder
Splitter group
Range-change group
Main transmission
(shifting, selecting)
014869 / 010834
Fig. 2.5
2-18
ZF-AS Tronic
024474
Fig. 2.6
The clutch actuator is flange-mounted on the integrated clutch bell housing of the transmission. The
clutch is actuated by the clutch actuator, which in
turn is actuated by the electronics in the transmission actuator.
Clutch actuator and transmission actuator are
connected (electrically) by the wiring harness
integrated in the clutch actuator and the relevant
transmission actuator connector (transmission end
connector).
In addition to the pneumatic actuation piston
responsible for the clutch release, the following
components are integrated in the clutch actuator:
Two cyclic valves are used each for opening and
closing the clutch, whereby both valves have rearmounted orifices of different diameters.
2-19
ZF-AS Tronic
2.4
Peripheral Components
2.4.1 ZF Selector Lever With Integrated E-Module and Additional ZF Extension Module
ZF Selector Lever
ZF extension module
ZF-CAN
ZF-AS Tronic
transmission electronics
027514
Fig. 2.7
A/M Changeover
+
+
S
DM
D
N
R
RM
Upshift
Cumulative
Upshift
=
=
=
=
=
=
A = Automatic
M = Manual
Downshift
Cumulative
Downshift
Search function*
Maneuver forwards
Drive (forwards, automatic or manual)
Neutral
Reverse
Maneuver in reverse
* If the S position (search function) is selected during manual operation and the engine brakes are not activated, the transmission shifts into the ECO gear (low engine speed).
If the S position (search function) is selected with the engine brake actuated, the transmission shifts into
POWER gear (high engine speed).
024451, 023867
Fig. 2.8
2-20
ZF-AS Tronic
As a further range selector variant, the new ZF
selector lever with integrated E-module can be used
for the ZF-AS Tronic system. This range selector
contains the electronics (E-module) needed for
recording, transfer, and activation:
15 mJ
I 2L
and
Lmanufacturer < 0,026 R2L
(If necessary, four more outputs can be depicted on
the lever-type range selector applications for
implementation can be clarified on request.)
NOTE
The cover (hood) do not fall within the standard ZF
scope of supply. Customer-specific parts should be
ordered separately.
More details of the lever-type and rotary switch
can be found in the installation drawings.
2-21
ZF-AS Tronic
2-22
ZF-AS Tronic
2.4.2
Additional interfaces
for ZF-AS Tronic
ZF extension module
ZF-CAN
ZF-AS Tronic
transmission electronics
024472
Fig. 2.9
2-23
ZF-AS Tronic
2.4.3 Display
The display shows operating displays, warning information, and system errors. The display communicated
with the transmission electronics via a ZF-specific interface. The display can if necessary be replaced by a
vehicle manufacturers interface-compatible display device.
OPERATING DISPLAYS
Display
Description
System self-check (with ignition ON)
024367
Drive maneuvering
024368
Transmission in Neutral
024369
PTO
- Arrow pointing upwards means PTO 1 is activated.
- PN means PTO (P) activated and transmission is in Neutral (N).
024370
PTO
- Arrows pointing upwards and downwards means PTOs 1 and 2 are activated.
- P1 means PTO activated and 1st gear engaged in transmission.
024371
024445
024444
Reverse maneuvering
024373
Manual operations
4th gear is engaged in the transmission.
024374
2-24
ZF-AS Tronic
WARNING INFORMATION
Display
Description
AL = Airless
Insufficient air pressure
024377
CC = Clutch check
Clutch position cannot be learnt.
024378
CL = Clutch
Clutch overloaded.
Select lower gear.
024379
CW = Clutch wear
Clutch worn.
024380
EE = Electronic error
Appears if communication between the display and transmission electronics is interrupted.
024381
FP = Accelerator pedal
Remove foot from accelerator.
024383
HT = High temperature
Excess transmission temperature.
024384
TC = Transmission check
Transmission positions cannot be learnt.
024386
2-25
ZF-AS Tronic
SYSTEM ERROR
Display
Description
System error !
Restricted further travel possible.
024387
S
T
O
P
024388
2-26
ZF-AS Tronic
2.5
Auxiliaries
2.5.1 Intarder
The Intarder is a hydrodynamic and therefore zerowear transmission brake. Transmission of product
families 3 and 4 can be supplied with a ZF-Intarder.
The ZF-Intarder is not available for product families
1 and 2.
2.5.1.1 General
2-27
ZF-AS Tronic
2.5.2
PTOs
2-28
ZF-AS Tronic
Integration
Additional attachment
Retrofitting
possible
not possible
2.5.2.4 Retrofitting
ZF-PTOs can be retrofitted on the ZF-AS Tronic.
Please observe installation instruction
6090 754 140 (product families 3+4) or
6090 754 150 (product families 1+2) and the OEMspecific connection and programming instructions
6090 754 ...
2-29
2-30
ZF-AS Tronic
Table of Contents
Description of Function
3.1
3.1.1
3.1.2
3.1.2.1
3.1.2.2
3.1.2.3
3.1.3
3.1.4
3.1.4.1
3.1.4.2
3.1.5
3.1.6
3.1.6.1
3.1.6.2
3.1.7
3.1.7.1
3.1.7.2
3.1.8
Basic Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Engagement Characteristics / Ignition On . . . . . . . . . . . . . . . . . . . . . .
Gear Selection With Vehicle Stationary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shifting from Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shifting From One Gear to Another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shifting to Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Selection during Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upshifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downshifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Protection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Overload Protection (also refer to Section 4.8.1.3) . . . . . . . . . . . . . .
Control of PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO Deactivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
3-4
3-4
3-4
3-4
3-4
3-5
3-7
3-7
3-8
3-8
3-10
3-10
3-10
3-11
3-11
3-12
3-12
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3-13
3-14
3-14
3-14
3-16
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3-17
3-17
3-17
3-18
3-18
3-19
3-19
3-1
ZF-AS Tronic
Table of Contents
3.4
3.5
3.5.1
3.5.2
3.5.3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On-Board Diagnosis (When Using the ZF Selector Lever) . . . . . . . . . . . . . .
Off-Board Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
3-21
3-21
3-21
3-21
ZF-AS Tronic
3
Function Description
Function Description
The function of the ZF-AS Tronic transmission system is sub-divided into two key blocks; the basic function
and the automatic drive program.
Basic function
CANinterface
receiving
converting
sending
Function
software
Signal
processing
shift process
clutch
diagnosis
actuator
activation
boot software
operating system
Activating
operating
mode
Operating modes
Help functions
Velicle CAN
028963_en
3.1
Basic Function
Detailed descriptions of the signals can if
necessary be found in signal specification ZF
no. 1328 761 005.
3-3
ZF-AS Tronic
Function Description
3.1.2
3-4
ZF-AS Tronic
Function Description
Phase 1
Phase 2
Phase 4
Accelerator (alphaFP)
Engine speed (nMot )
Transmission input speed (nGe)
018991_en
The starting gear for forward driving can be corrected by the driver. On the basis of the starting gear
selected by the (automatic) shifting strategy, and
depending on the application, free gear selection is
possible either upwards or downwards, including
the maximum starting gear. Depending on the application, the maximum starting gear for the 12-speed
Phase 3
3-5
ZF-AS Tronic
Function Description
If thermal overloading arises during the second
phase, the driver is informed of this via the display.
The nominal engine speed is continuously reduced
at the same time. This is achieved by successively
closing the clutch. The nominal engine speed can be
reduced until the engine stalls.
3-6
ZF-AS Tronic
Function Description
3.1.4.1 Upshifts
Engine speed
Clutch closed
Clutch open
B2
Gear engaged
Transmission in Neutral
Transmission brake Off
Transmission brake On
Speed adjustment
Time
B1 C
D E
F G
018992
Fig. 3.3
B1
Partial opening of clutch and at the same time reduction in load by reducing the fuel injection
volume.
B1
B2
C
C
3-7
ZF-AS Tronic
Function Description
3.1.4.2 Downshifts
Engine speed
Synchronize
Clutch open
Gear engaged
Transmission in
Neutral
Time
BCD
E F
G
018993
Fig. 3.4
Partial closing of clutch and blipping of throttle by briefly increasing fuel injection volume.
Transmission shift elements are brought up to connecting speed of gear to be selected.
Once shift elements are at the same speed, the clutch opens and the transmission actuator selects
the gear requested.
When Gear selected signal is displayed, clutch begins to close in parallel to build-up of load.
3.1.5 Maneuvering
closed position and the target engine speed increases.
Sliding friction is produced on the friction interfaces
as a result of the partially closed clutch. The transfer
torque on the clutch is set by the control unit so that
drive resistance is surmounted. The vehicle can
thereby be moved slowly and sensitively forwards or
backwards using the accelerator.
3-8
ZF-AS Tronic
Function Description
There is no automatic gear change during
maneuvering. A gear change must be requested
manually by the driver using the range selector.
018988_en
3-9
ZF-AS Tronic
3.1.6
Function Description
In this instance, the driver receives both visual and
acoustic warnings (passive protective measure).
The warning is reset once a defined lower load limit
value is reached.
Protective Functions
NOTE
This function must be discussed by the customer
and ZF.
Slip time
Clutch:
Difference
in speed
Driver
information
Algorithm
for protecting
against
clutch
overload
n
n
Driver
influence
Clutch
activation
P
Engine
torque
T
m
018964
Fig. 3.6
3-10
ZF-AS Tronic
Function Description
NOTE
The transmission control unit (TCU) only checks
transmission-internal conditions for the acceptance
of PTO operation.
The vehicle manufacturer is responsible for the
safety-related requirements of PTO operation.
Product families 1 + 2:
PTOs can be operated via both constants of the
splitter unit (see power-flow diagram, Section 2.2).
Which of the two constants is active in neutral position of the transmission depends on the software.
As regards mobile PTOs, all starting gears and all
rear gears are possible.
Product families 3 + 4:
PTOs may only be operated via the constant K1 (see
power-flow diagram / Section 2.2). The slow splitter
ratio is thus always engaged on direct-drive transmissions while the fast splitter ratio is always
engaged on overdrive transmissions.
As regards stationary/mobile PTOs, the gears R1, 1,
3, 5 and 7 are possible (gear 7 only in the 16-speed
version) in the direct-drive version while the gears
R2, 2, 4 and 6 are possible in the overdrive version
(gear 6 only in the 16-speed version).
3-11
ZF-AS Tronic
Function Description
3-12
ZF-AS Tronic
3.2
Function Description
Other
ABS/DTC
Transmission
Intarder
Engine
Optimum setting
off gear
ISMA
nominal gear
028666_en
Driver
3-13
ZF-AS Tronic
Function Description
Numerous calculations, parameters and characteristics curve evaluations, and interpolations are needed
for the different operating modes. Vehicle status
parameters, such as present vehicle acceleration and
the present traction or coasting torque are calculated
in these help functions. The drive resistance and the
mass calculation are key influencing parameters for
determining the shift point. Other status parameters,
such as speed and the acceleration of the transmission shafts and an estimate of the vehicle mass
when setting off, are used for a harmonic drive
strategy.
3-14
ZF-AS Tronic
Function Description
If this shift speed is above the maximum shift speed
area, the change in ratio and/or speed must be
recalculated. The limit points in the upper speed
range result from the accelerator position and
acceleration of the transmission input speed. The
ratio step is therefore determined via the shift speed
calculation.
kW
300
P_mot
350
250
Supplementary
value for increased
drive resistance
Speed loss
through drive
resistance of shift
Valid
shift
speed
Upper shift
speed limit
range
Change in speed
brought about by
ratio change
200
150
100
50
Acceleratordependent
0
-50
-100
600
Target speed
800
1000
1200
Shift speed
calculated from
target speed
1400
1600
1800
2000
N_mot
U/min
018978_en
2200
3-15
ZF-AS Tronic
Function Description
3-16
ZF-AS Tronic
3.3
Function Description
The following were identified as safety-related
malfunctions as defined in VDI/ VDE 3542 Page 1 in
the risk analysis:
3.3.1 Principles
The ZF-AS Tronic is an automatic system, which
unlike conventional driveline components, takes on
all or some of the processes controlled by the driver.
In some instances, responsibility for these processes
passes from the driver to the system. In order to fully
satisfy this level of responsibility, the ZF-AS Tronic
transmission system has been subjected to a state-ofthe-art technical system error analysis.
3-17
ZF-AS Tronic
Function Description
electric
pneumatic
Clutch actuator
Nonreturn
valve
Control and
display elements
Range
selector
MV4
Rotary
switch
MV3
Sensor
Vehicle circuit
interfaces for
ZF-AS Tronic
MV2
Display
ZF extension
module
MV1
Transmission actuator
Sensor
Range-change group
Sensor
Pressure
relief
valve
Pressure
sensor
ZF-AS Tronic
transmission
electronics
Splitter
Sensor
Select
Sensor
ZF-CAN
ABS
ASR
Intarder
Engine
electronics
Shift valves
Y1
Y9
Main transmission
Vehicle CAN
027623
3-18
ZF-AS Tronic
Function Description
3-19
ZF-AS Tronic
3.4
Function Description
Error class 1
Error Responses
No error display.
Entry in error memory.
Possibly reduced driving comfort.
Error can be rectified during next visit to workshop.
Error class 2
Restricted operation available
Error display (Screwdriver symbol).
Entry in error memory.
Reduced driving comfort.
Error class
Displays
None
S
T
O
P
Error class 3
No further operation available.
Error display (STOP and Screwdriver symbol).
Entry in error memory.
No further gear shifting during travel, the gear
selected is retained.
When the vehicle comes to a standstill, a shift is
made to Neutral, no further travel available.
Contact nearest specialist workshop.
3-20
ZF-AS Tronic
3.5
Function Description
Diagnosis
Testman pro, ZF diagnosis system for PC applications incl. ZF diagnosis adapter DPA 05 and connection cable with ISO and/or SAE connection;
For description, refer to type sheet for
ZF-Testman pro.
Test device
(displays all digital inputs and outputs);
Displaying digital and analog parameters e.g.
speeds, current strengths, and voltage levels.
When undertaking specific troubleshooting, this
device allows staff trained by ZF to rapidly find
the error in the transmission system. Once the error
has been detected, the diagnosis system proposes
remedial measures.
Communication occurs in the form of a serial interface. Each screen page can be printed out or saved
for error documentation. The diagnosis software is
available in all major languages.
3-21
ZF-AS Tronic
Function Description
Terminal tester
A terminal tester, complete with adapter for 20 and/
or 18-pin plug connections is available for the electrical troubleshooting of input and output signals of
the vehicle interface to the ZF-AS Tronic.
3-22
ZF-AS Tronic
Table of Contents
Installation
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
4.1.10
4.1.11
4.1.11.1
4.1.11.2
4.1.12
4.1.13
4.1.14
4.1.15
4.1.16
4.1.17
4.1.18
4-5
4-5
4-5
4-5
4-6
4-6
4-8
4-9
4-10
4-13
4-14
4-18
4-18
4-18
4-19
4-19
4-19
4-19
4-20
4-21
4-21
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Permissible Ambient Temperatures on Transmission . . . . . . . . . . . . . . . . . .
Permissible Oil Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Causes of Excess Oil Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Transmission Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use in Sub-Zero Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22
4-22
4-22
4-22
4-23
4-24
4-24
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4-25
4-25
4-25
4-26
4-26
4-26
4-27
4-27
4-28
4-1
ZF-AS Tronic
Table of Contents
4.4
4.4.1
4.4.2
4.4.2.1
4.4.2.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.7.1
4.4.7.2
4.4.8
4.4.9
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Layout and Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector on Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Connector to Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN Bus Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quality Requirements of Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector and Mating Connector Designations . . . . . . . . . . . . . . . . . . . . .
Other Electrical Interfaces on the ZF-AS Tronic . . . . . . . . . . . . . . . . . . . . . .
Neutral Switch (S12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5
Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.6
4.6.1
4.6.2
4.6.3
4.6.4
4.6.5
Auxiliaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF-Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third Party Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZF Power Take Off Units (PTOs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third Party PTOs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-41
4-41
4-41
4-41
4-42
4-42
4.7
4.7.1
4.7.2
4.7.3
4.7.4
4.7.5
4.7.6
4.7.7
4-42
4-42
4-43
4-43
4-43
4-43
4-44
4-45
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Off, Forward Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maneuvering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maneuvering via the accelerator pedal
with rotary switch in D or R position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.1.3.2 Maneuvering acc. to rotary switch position DM or RM . . . . . . . . . . . . . . . .
4-46
4-46
4-46
4-47
4-47
4.8
4.8.1
4.8.1.1
4.8.1.2
4.8.1.3
4.8.1.3.1
4-2
4-29
4-29
4-30
4-30
4-31
4-32
4-33
4-35
4-36
4-37
4-37
4-37
4-37
4-38
4-47
4-48
ZF-AS Tronic
Table of Contents
4.8.1.4
4.8.1.5
4.8.1.6
4.8.1.7
4.8.1.8
4.8.1.9
4.8.1.10
4.8.1.11
4.8.1.12
4.8.1.13
4.8.1.14
4.8.1.15
4.8.1.16
4.8.1.17
4.8.2
4.8.2.1
4.8.2.2
4.8.3
4-48
4-48
4-49
4-49
4-50
4-50
4-50
4-50
4-51
4-51
4-52
4-52
4-53
4-53
4-54
4-54
4-54
4-54
4.9
4.9.1
4.9.2
4.9.3
4.9.4
4-55
4-55
4-55
4-55
4-56
4-3
4-4
ZF-AS Tronic
Installation
Installation
4.1
019424
Engine connection
SAE 1
[PF 1+2]
[PF 3+4]
109 mm
32 mm
31.75 mm
75 mm
102.3 mm
25 f7 mm
50.3 mm
SAE 10 C 2
4-5
ZF-AS Tronic
Installation
4.1.5 Clutch
4-6
ZF-AS Tronic
Installation
Product family
3+4 SAE 1
Clutch type
430 pulled
395 pulled
430 pulled
max. inertia
torque
0.119 kgm2
0.082 kgm2
0.145 kgm2
4-7
ZF-AS Tronic
Installation
To design the push rod, ZF needs the dimensions
(A, X, Y, and Z) and tolerances shown in Fig. 4.1.
These are acquired in the customer specification.
CAUTION
If the ZF-AS Tronic or ZF-AS Tronic mid is used for
the transport of dangerous goods, additional
measures will be required on the clutch actuator.
Contact your ZF partner for more details.
Y
X
approx. 34 mm max. travel of release bearing
A engine connection
dimension
Housing flywheel disc
X release + tolerance
Y wear + tolerance
Z installation dimension clutch
019500
4-8
ZF-AS Tronic
Installation
Magnetic stand
Crankshaft
and
the connection area on the engine
may only deviate from the geometrically ideal
position within certain limits.
Dial gage
016855
Engine housing
Dial gage
Flywheel
Crankshaft
Magnetic stand
Pilot bearing
016856
Dial gage C
Engine housing
Flywheel
Crankshaft
Magnetic stand
016857
1328 765 101 - 2007-10
4-9
ZF-AS Tronic
Installation
ZF proposal for suspension
4.1.8 Suspension
Only the screw surfaces on the transmission housing
and/or on the attachment unit intended for the purpose may be used for the transmission suspension.
Housing material GD-AlSi9Cu3 is defined as the key
strength values for the screw configuration, material
F270 and surface treatment Fe/Zn6B DIN 50961 are
defined for versions with threaded bushes.
027475
Continuous
carrier
Fig. 4.3
4-10
018902
ZF-AS Tronic
Installation
NOTES
Other threaded bores are not permitted as
suspension points on the ZF-AS Tronic.
Minimum screw-in depth of 32 mm for screw
connections in housing material, minimum
screwing depth of 24 mm for screw connections
in threaded bushes.
Maximum permissible vertical loading 3 g on
point D. Otherwise support needed for D.
DANGER
The bending torque MC of the bearing supports
on mounting face C must not exceed the limit
value of 1 900 Nm.
Lateral suspension at point C is not possible in pressure die casting housings of product families 1+2.
If suspension is required at point C, a sandcast housing must be applied.
For calculation of MC, refer to Fig. 4.6.
4-11
ZF-AS Tronic
Installation
C
a
b
c
Fc
Fc
2
016999
Fig. 4.4
4020
Fc
Fc
Fc
2
Fig. 4.5
017000
016998 / 019462
Fig. 4.6
MC =
l (mM a + mG c) g
b2
4-12
ZF-AS Tronic
Installation
Installation angle
(longitudinal)
Camber of road
(transverse)
30 %
30 %
Continuous
10 %
50 %
50 %
1 min
21 %
40 %
Period
40 %
60 %
1 min
(20 % with
longitudinal
camber of road
of 0 %)
0
Front
installation
at 5
4-13
ZF-AS Tronic
Installation
Rotary angle
1.8
1.6
1.4
1 rev.
1.2
1.0
0.8
0.6
0.4
0.2
1000
Fig. 4.8
0
0.1
1 rev.
S 0013
perm. 1 500
S0014
+0.1
0.2
3000
0.2
2000
[] n2 [rpm2]
rad
=
s2
1 306
4-14
ZF-AS Tronic
Installation
V=13
tan2 H + tan2 V
tan R =
H = 9
R = 15.6
Acc. to diagram:
R 15
S0012
CAUTION
For PTOs, the permissible deflection angle R must
not exceed 7.
Deflection anlgle R
007927
20
16
14
12
10
8
6
4
20
25
10
15
5
0
9 10
15
20
Flange 165/180/225
500
1000
1500
2000
2500
3000
3500
4000
007098_en
10
Flange 150
max. 7 at PTO
20
13
Product range
30
15
18
25
001100
4-15
ZF-AS Tronic
Installation
Propshaft calculation programs (graphic depictions) can be ordered from the Printing and
Logistics department (documentation.zff@zf.com)
by specifying the following numbers:
CD-ROM (0000 766 707), diskette (0000 766 708).
Basis: Windows 3.11, 95, 98, NT
The following applies as the prefix rule for the individual angles :
+ if the spider is
vertical
to the output fork
Input
Output
90
if the spider is
vertical
to the input fork
Limit value:
90
Input
Output
S0010
E < 3
Z-arrangement
W-arrangement
Angle error
= 1 2
Example 1
(exact Z
and/or W
arrangement)
Example 2
(small
bending
angle with
angle error)
Example 3
(large
bending angle
with angle
error)
12 + 22
1 =12
1 =12
2 = 12
2 = 12
5,4
1= 5
1= 5
2 = 4
2 = 4
1 = 15
1 = 15
2 = 14
2 = 14
Example 3 shows that with larger deflection angles, even an angle error of 1 results in excessively high joint deflection angles.
Fig. 4.12 Application examples for the influence of the deflection angle parameters
1 and 2 on the resultant deflection angle
4-16
S 0011
ZF-AS Tronic
Installation
Simple configurations
Multiple arrangements
1
Transmission
S0015
Leaf spring suspension results from favorable Z arrangements caused by parallel axle arrangements.
Condition 1 = 2 is maintained to some extent even when
the suspension bottoms out.
Unfavorable arrangement
E =
12 + 22 32 = (13.6)
1 =9.5
h
Spring travel
2 =5
laden
empty
Transmission
3 =11
Axle movement
An oscillating axle results from unfavorable Z arrangements caused by axle oscillation movements.
Condition 1 = 2 is only satisfied in the central position.
When the suspension bottoms out, these angles cease to be
the same.
Axle
Optimized arrangement
(by changing the spider position)
E =
12 22 + 32 = (2.4)
1 =9.5
h
Oscillation travel
laden
-0+
Transmission
central position
2 =5
Axle
=11
Axle movement
S0016
S0017
4-17
ZF-AS Tronic
Installation
More information
Balancing:
The propshaft must be dynamically balanced
using quality level as defined in VDI Guideline
2060 (Fig. 4.15).
200
150
TMot.
100
Full
load curve
Volllastkurve
+15%
+15%
100%
80
zulssige
Permissible
Schwingungspeak
berhhungen
vibrations
16
250
60
40
30
300
500
700 900
1500
3000 4000
nMot.
S0018
007099
Centering
fit
h7
Lubrication:
The specifications issued by the propshaft
manufacturer should be noted for lubrication.
The sliding piece must be able to move easily
when under load.
4-18
ZF-AS Tronic
Installation
Permanent loading:
5 g (< 30 Hz)
7 g (< 30 Hz)
CAUTION
Fording ability is not a standard feature of the
ZF-AS Tronic or the ZF-AS Tronic mid.
Versions of the ZF-AS Tronic and ZF-AS Tronic mid
(SAE2 flange version) featuring fording ability can
be supplied upon request.
4-19
ZF-AS Tronic
Installation
4.1.16 Accessibility
The following parts of the ZF-AS Tronic (refer to
Figure 016859) must be accessible for identification,
test, maintenance, and repair purposes.
Type plates of the ZF range selector module / ZF
extension module (refer to drawing 6041 622 026),
transmission actuator, and transmission (refer to
installation drawing).
Oil filler plug, oil drain plug, and overflow
measurement (refer to installation drawing).
Compressed air connection at least 40 mm
clearance (for all connections).
*Servicezwecke
Please keep theist
* Fr
installation
area clear
dieser
Aus-/Einbauraum
12
110*
50*
150*
028964
4-20
ZF-AS Tronic
Installation
4-21
ZF-AS Tronic
4.2
Temperatures
Installation
4.2.2 Permissible Oil Temperatures
For CV applications with and without intarder, a
permanent temperature of 110 C is permitted,
measured in the transmission oil sump. Short (max.
30 min.) peaks in temperature of up to 130 C are
permitted. In total, these peak values may make up
max. 10 % of the oil change interval.
For special vehicles (cranes, fire service vehicles
etc.), we also recommend temperature measuring
runs. The same permissible temperatures as those
for normal commercial vehicle applications apply.
4-22
ZF-AS Tronic
Installation
Product families 3 + 4:
-
Product families 3 + 4:
An external oil-water heat exchanger can either
be fitted in the factory and supplied with the
ZF-AS Tronic or retrofitted onto the ZF-AS Tronic.
In the event of subsequent attachment, painting
of the heat exchanger must not be forgotten (cf.
Section 4.7.4).
The cooling rating of the heat exchanger can be
taken from the installation drawing (refer to installation drawing + heat exchanger, Section 4.1.1).
There must be a by-pass line (by-pass valve, 1.0 bar)
upstream of the heat exchanger between the heat
exchanger inlet and heat exchanger outlet ends.
The transmission must not be operated while the
heat exchanger is not connected up.
Product families 1 + 2:
The transmission can be fitted with an integrated
heat exchanger and therefore does not need an
external by-pass valve.
Chap. 4.3 and the relevant installation drawings
should be noted with regard to filling oil and the oil
level check in conjunction with a heat exchanger.
4-23
ZF-AS Tronic
Installation
Down to 20 C
20 C to 30 C
30 C to 40 C
Oil grade
Engine start
Permitted
Permitted
Transmission must be
preheated before the engine
is started.
When starting,
note
Limitations
None
At transmission temperatures
in excess of 20 C, the transmission is operable and all
functions are provided.
Longer shift times should be
expected.
At transmission temperatures
in excess of 20 C, the transmission is operable and all
functions are provided.
Longer shift times should be
expected.
NOTE
Air leakage on the transmission system will significantly increase at temperatures below 20 C. It is not sure
that the clutch can be opened for the engine to start in this temperature range.
In such a case, the engine-based starter must be able to overcome the the drag torque of the transmission in
addition to that of the engine.
4-24
ZF-AS Tronic
4.3
Installation
Non-Intarder transmission
7.8
7.5
Product family 2
9.3
Product family 3
12-speed
12
11
Product family 3
16-speed
13
12
Product family 4
16-speed
13
12
For oil fill quantities concerning transmissions with Intarder, refer to ZF-Intarder technical manual.
Order no. 6085 765 104
4-25
ZF-AS Tronic
Installation
DANGER!
Touching hot parts and transmission oil may cause
burns.
CAUTION
In case of a transverse transmission installation
angle, ensure that the transverse inclination
corresponds to 0 for filling in the oil, otherwise
the oil quantities will be incorrect.
The position of oil fill apertures and the oil fill
plugs can be seen in the relevant installation
drawing (Section 4.1) and the technical manual for
the Intarder (ZF no. 6085 765 104).
DANGER !
Too little oil in the transmission will result in transmission damage. Risk of accident!
4-26
ZF-AS Tronic
4.3.6 General Information
Even if reference is made here and in the
aforementioned documents to particular volumes,
ensure that the oil level is correct on the transmission itself. To do this, one of the oil fill apertures
in the horizontal vehicle must be filled with oil until
the level has reached the lower edge of the fill aperture and/or oil is escaping from this fill aperture.
For Intarder applications and applications with heat
exchangers, please note that the the oil is only filled
fully once the vehicle has been moved and a second
filling process is reached (refer to technical manual
for Intarder ZF no. 6085 765 104).
Installation
4.3.7 Information about Bleeding the
Transmission
The transmission is fitted with a vent on the
transmission actuator as standard. The vent should
be protected from the ingress of large amounts of
water. The breather must be clean and must not
have its plastic cover fitted. In special applications,
such as off-road vehicles, refuse collecting vehicles
and milk collecting vehicles, which are frequently
cleaned using a jet of water, moisture or moist air
may be drawn into the vent as a result of sudden
transmission cooling, causing condensation to form
inside the transmission.
Since the proportion of water in the transmission
oil must not exceed 1 000 ppm, rather than the
standard vent, ZF recommends that a a hose-type
vent be installed in the vehicles dry compartment.
The interface on the transmission to the hose may be
supplied having been fitted in the factory. A retrofit
kit for hose venting is available under ZF number
1315 298 021 from ZF-Service.
4-27
ZF-AS Tronic
4.3.8 Venting by Means of Hose Line in Dry
Compartment
ZF recommends this type of venting as standard.
This provides the best possible protection for the
transmission against water ingress. When using this
form of hose venting, the oil change interval for
ECOFLUID M transmission oil increases. More
information on this can be found in the List of
Lubricants TE-ML 02.
Notes on the dry compartment and routing of the
hose:
Installation
Max. permissible hose temperature (e.g. near
exhaust pipes, exhaust turbo charger) must not be
exceeded.
End of hose lowered by approx. 150 mm.
Light width of hose of at least 4 mm.
Fording capability according to vehicle specification must be retained.
The vehicle manufacturer is responsible for the
correct fitting and routing of the hose.
correct
incorrect
023915
4-28
ZF-AS Tronic
4.4
Installation
Electrics
Range selector
Display
Additional interfaces
for ZF-AS Tronic
Serial line
Rotary
switch
ZF-CAN
ZF-AS Tronic
Engine
electronics
Voltage supply
Diagnosis
Speedo signal
027621
Range selector
Additional interfaces
for ZF-AS Tronic
Dashboard
OEM bus
Central
vehicle computer
Engine
electronics
Vehicle CAN
ZF-AS Tronic
Engine
electronics
ABS
Electronics
for
ZF-Intarder
Voltage supply
Diagnosis
Speedo signal
Electronics
for
ZF-Intarder
ABS
Vehicle CAN
If the vehicle is equipped with a vehicle master computer, the signals to/from the levertype range selector, display, R gear relay etc.
can be sent by it to the ZF-AS Tronic via the
vehicle CAN (Fig. 4.18).
The circuit diagram is the electrical wiring
diagram for the ZF components in the
system layout. It is used to establish the
wiring; the connectors of the ZF components are also depicted for this purpose.
If the wiring for connecting ZF components
to the transfer connector (vehicle supply
connector in E box) is supplied by ZF, then
ZF also draws up a connection diagram.
ZF extension
module
4-29
014 880
ZF-AS Tronic
Installation
Pin
20-pin
Pin
18-pin
Name
Explanation
VMGA2
ADS 1
ADS3
ADS2
10
10
EU1
11
11
EF
12
12
ADS4
15
15
AU
16
16
VM1
17
17
VM2
18
18
ADVP
20
VGMA1
* This output is electrically connected to the ADVP1 output (vehicle supply connector to vehicle)
4-30
ZF-AS Tronic
Installation
Pin
Pin
20-pin 18-pin
Name
Explanation
VPI
SDDK
CANF2-H
ZFs own CAN interface (CAN high signal), line color: red,
interface between transmission electronics and ZF components.
VPE1
VPE2
CANF2-L
ZFs own CAN interface (CAN low signal), line color: black,
interface between transmission electronics and ZF components.
SDEF
CANF1-H
SD
10
10
SDP
11
11
ADVP1
12
12
CANF1-L
4-31
ZF-AS Tronic
Installation
Pin
Pin
20-pin 18-pin
Name
Explanation
13
13
CANF1-L+
14
14
CANF1-H+
15
15
CANF1-T
16
16
VM1
Ground / Earth supply 1 (route VM 1 and VM2 with separate line routing on
vehicle ground / earth star point)
17
17
VM2
Ground / Earth supply 1 (route VM 1 and VM2 with separate line routing on
vehicle ground / earth star point)
18
18
VMHF1
Connection option for possible CAN line sheathing (high frequency ground/earth)
19
VMHF2
Connection option for possible CAN line sheathing (high frequency ground/earth)
20
VM3
18 - 32 V DC
36 V, 40 C 1h
4-32
ZF-AS Tronic
Installation
R1
Line version
The line version must also be designed in accordance with existing standards (SAE J 1939 and/or
ISO/DIS 11898), which specify twisted and/or
twisted + sheathed.
Electronics
A
Electronics
B
CAN_H
CAN_H+
CAN_L
Electronics
n
R1*
CAN_L+
CAN_H
014881
CAN_L
Fig. 4.19
Electronics
A
Electronics
B
Point A
Electronics
C
Electronics
n
Point A
R1
R1*
CAN_H
Point B
CAN_L
014882
Point B
Fig. 4.20
4-33
ZF-AS Tronic
Installation
Vehicle wiring
TCU
8 CANF1-H
14 CANF1-H+
CAN_H
Terminating
resistor
CAN_H
free
120
Ohm
15 CANF1-T
13 CANF1-L+
CAN_L
HF-ground
12 CANF1-L
CAN_L
18 VMHF1
HF-ground opt.
19 VMHF2
HF-ground opt.
028965_en
4-34
ZF-AS Tronic
Installation
Vehicle wiring
TCU
CAN_H
Terminating
resistor
8 CANF1-H
CAN_H (TCU A)
14 CANF1-H+
CAN_H+ (TCU B)
120
Ohm
15 CANF1-T
CAN_L
free
12 CANF1-L
CAN_L (TCU A)
13 CANF1-L+
CAN_L+ (TCU B)
18 VMHF1
HF-ground opt.
19 VMHF2
HF-ground opt.
HF-ground
028966_en
The wiring should be routed and secured in a protected part of the vehicle. The cable must be secured
at a maximum of 20 cm downstream of the transmission power supply connector. Loose hanging
wiring is not permitted.
The connectors must not be tightened down too
firmly. Ensure that the connectors and mating
connectors are compatible and snapped in.
Also ensure that there are no relative movements,
e.g. between vehicle frame and transmission, which
damage the wiring.
The securing material must be selected ensuring that
the wiring is neither squashed nor damaged or
pre-damaged in any way.
CAUTION
A sufficient distance should be maintained from
sources of heat, such as exhaust, heat exchanger
etc. and/or thermal protection should be fitted.
Other techn. requirements can be found in
TKI 6029 705 003.
4-35
ZF-AS Tronic
Installation
Use
Type
Manufacturer ZF Number
Manufacturer no.
CKD no.
Protection class
X1
Transmission
actuator (TCU)
20-pin bush
Kostal
IP 67/ 69
X1
Transmission
actuator (TCU)
Special version
18-pin bush
Kostal
IP 67/ 69
X5
Display
Refer to 6-pin
connector MNL
Refer to 6-pin
connector MNL
Refer to 6-pin
connector MNL
Open connector
system;
No details for
protection class
Refer to 6-pin
connector MNL
X5
X5
Display
Display
4-pin
AMP
connector MNL
X21
Diagnosis
6-pin
AMP
connector MNL
X21
Diagnosis
Mating connector
Connector housing:350715-1
Contact bush: 926882-3
X2a
ZF selector lever
15-pin bush
(with integr. E module) MCP 3-row
AMP
Open connector
system;
X2b
ZF selector lever
9-pin bush MCP AMP
(with integr. E module) 3-row
No details for
protection class
X36a
AMP
Open connector
system;
X36b
AMP
No details for
protection class
X50a
Extension module
18-pin bush
MCP 3-row
AMP
Open connector
system
X50b
Extension module
15-pin bush
MCP 3-row
AMP
No details for
protection class
A11/A14
Output sensor
IP 67/ 69K
S12
Neutral switch
IP 67/ 69K
X17
Refer to 6-pin
connector MNL
X17 A
Main power system
Mating connector junction
Refer to 6-pin
connector MNL
X18
18-pin bush
JPT 2-row
Refer to 6-pin
connector MNL
Connector housing:929505-6
Pin contact: 928930-5
Refer to 6-pin
connector MNL
Refer to 6-pin
connector MNL
Refer to 6-pin
connector MNL
Refer to 6-pin
connector MNL
Connector housing:929505-6
Pin contact: 928930-5
Refer to 6-pin
connector MNL
AMP
X18 A
Main power system
Mating connector junction
X18 A
Main power system
Mating connector junction CAN
X18 A
Main power system
Mating connector junction CAN
X19
18-pin bush
JPT 2-row
Cab junction
X20 Mating
Cab junction
connector to X19
1328 765 101 - 2007-10
AMP
4-36
ZF-AS Tronic
Installation
Comments:
If the Neutral signal is delivered by CAN, the
mechanical neutral switch is not needed.
This variant is recommended by ZF.
G32
1:1
39
1.5
23.6
1
2
SW27
W.A.F.
027564
4-37
ZF-AS Tronic
Installation
4-38
ZF-AS Tronic
4.5
Installation
Pneumatics
In example 1, the air supply for the braking
system takes priority over the shift system, since
an relief valve (> 5 bar) is mounted in front of the
ZF-AS Tronic air circuit.
The pressure level set on the relief valve must
however be less than the pressure level of the
relief valves in the 4-circuit protection valve for
the auxiliary consumers.
Example 1
4-circuit
protection
valve
Compressor
Air drier
Overflow
valve 5 bar*
Transmission
actuator with
pressure sensor
D-I = 9 mm
20 L
Clutch
actuator
Non-return valve
D-I = 9 mm
max. 4 m
* The pressure level set on the relief valve MUST be less than the pressure level of
the relief valves in the 4-circuit protective valve for the auxiliary consumers.
Example 2
4-circuit
protection
valve
Compressor
Air drier
Transmission
actuator with
pressure sensor
D-I = 9 mm
20 L
Clutch
actuator
Non-return
valve
D-I = 9 mm
max. 4 m
Auxiliary
consumer
014885 / 014886
Fig. 4.24
1328 765 101 - 2007-10
Overflow
valve
5 bar
4-39
ZF-AS Tronic
Installation
Air reservoir
Air lines
Air pressure
Supply pressure
Air quality
The compressed air made available to the vehicle
must be cleaned, dried and free of condensate.
Air particle filter: 40 microns mesh width.
= Pressure in transmission
actuator downstream of
pressure relief valve
= Pressure in air reservoir
Water content
[g/m3]
0.136
0.332
0.726
1.41
2.6
4.55
7.66
DANGER!
If gear shifts are undertaken with insufficient air
pressure, the transmission may remain in Neutral so
that there is no direct drive and no engine brake
effect.
4-40
ZF-AS Tronic
4.6
Installation
If ZF expressly refuses to issue approval for a third
party retarder, then ZF assumes no warranty or liability for this unit combination, or for the functional
and operating safety of the entire system.
Auxiliaries
4.6.1 ZF-Intarder
The ZF-Intarder cannot be retrofitted. The ZFIntarder must always be taken into consideration
when ordering the transmission.
Special features of oil fills for the ZF-AS TronicIntarder combination can be found in the ZFIntarder technical manual (ZF no. 6085 765 104).
Initial installation of a ZF-AS Tronic and ZF-Intarder
system combination must be commissioned and
approved by ZF.
4-41
ZF-AS Tronic
Installation
4.7
4.7.1 Transport
Only the lugs fitted on the transmission mounting on
housings 1 and 3 may be used for transport purposes.
019529
ZF-AS Tronic
019530
4-42
ZF-AS Tronic
Installation
018495
4-43
ZF-AS Tronic
Installation
The delivery status of the ZF-AS Tronic is documented by ZF using the vehicle manufacturers
order number.
ZF-AS Tronic-specific data which has to be documented by ZF is discussed with the OEM.
4-44
ZF-AS Tronic
Installation
027587
4-45
ZF-AS Tronic
4.8
Installation
Additional Information
4.8.1 Operation
Safety Instructions
The following safety instructions appear in this manual:
NOTE
Refers to special processes, techniques, data, etc.
CAUTION
This is used when incorrect, unprofessional
working practices could damage the product.
DANGER!
This is used when lack of care could lead to
personal injury or material damage.
DANGER!
The vehicle must not be left with the engine
running and a gear selected.
Gears cannot be selected if there is no engine
function (e.g. no fuel), transmission selects
Neutral. Engine brake and steering assistance
will fail during travel.
023867
024367
Self-check complete.
N appears on display,
transmission is in Neutral.
024369
NOTE
Gears cannot be selected when engine is stationary.
4-46
ZF-AS Tronic
Installation
4.8.1.3 Maneuvering
024376
DANGER!
The vehicle may start to roll away even if you do not
depress the accelerator.
D N R RM
Hill start
DANGER!
Select gear, only release parking brake once
accelerator has been depressed otherwise the
vehicle will roll backwards.
D N R RM
DM
027515
DM
D N R RM
D N R RM
DM
Undertaking correction:
or + / + direc-
027516
4-47
! DANGER!
If the driver does not respond to the
CL display, the system changes
from maneuvering mode to setting
off.
The vehicle may accelerate.
Risk of accident!
ZF-AS Tronic
Installation
DANGER !
The system changes from maneuvering mode to setting off depending on the accelerator position and
vehicle speed.
The vehicle may accelerate.
Risk of accident!
DANGER!
When the vehicle moves off without a gear
selected rotary switch in position N
the engine brake will not work!
Do not allow vehicle to roll in direction opposite
to that of the gear selected.
D N R
D N R
M
CAUTION
If the driver does not respond to
the CL display, the clutch may
be damaged from overload.
A/M
4-48
ZF-AS Tronic
Installation
DANGER!
If the vehicle is rolling, a shift is not made into
reverse gear!
Immediately bring the vehicle to a standstill.
024376
DANGER!
Changing direction of travel by moving the rotary
switch from R/RM to D/DM and vice versa may
only be undertaken when the vehicle is stationary,
otherwise the transmission shifts to Neutral.
The display is definitive for the direction of travel
selected in the transmission.
NOTE
You can shift from any gear to Neutral at anytime
using the rotary switch. This shift request takes
priority over other requests.
The accelerator position must not be changed during the shift process because the engine is controlled electronically.
A shift command is not undertaken if the shift
would result in the max. permissible engine speed
being exceeded.
DANGER !
Shifts to Neutral can also be made during travel. If a
shift is made to Neutral, the driveline is interrupted.
The engine brake then no longer functions.
4-49
ZF-AS Tronic
4.8.1.8 Engine Brake
!
DANGER!
The engine brake function is interrupted during the
gear shift. The vehicle may accelerate when traveling
downhill.
Manual operations
The engine brake is deactivated by the system
during gear shifts. Once the gear shift is complete,
the engine brake is automatically reactivated.
Automatic operation
By activating the engine brake, the system downshifts so that maximum braking torque is reached.
4.8.1.9 Stopping
With the accelerator untouched, slow down the
vehicle using the service brake until it reaches a
standstill.
The clutch opens automatically before the vehicle
reaches a standstill so that the engine does not
stall.
If the vehicle is going to be stationary for long
periods of time, we would recommend selecting
the Neutral transmission position.
Always engage the service or parking brake when
the vehicle is stationary.
DANGER!
When the vehicle is stationary with the engine
running and a gear selected, you need simply press
the accelerator in order to move the vehicle!
Before leaving the vehicle with the engine running,
the transmission must be shifted into Neutral and
the parking brake engaged.
Activating the parking brake during travel and on a
smooth surface may bring the engine to a
standstill. Steering assistance is then no longer
available!
Installation
4.8.1.10 Switching Off Engine / Stopping Vehicle
DANGER !
The engine cannot be switched off if a gear is
selected.
The vehicle may roll away if no brakes are engaged.
Engage parking brake.
NOTE
If the transmission is not shifted to Neutral before
the engine is switched off, this is done automatically
when the ignition is moved to Off .
4.8.1.11 Towing
The vehicle can be towed with a flange-mounted
propshafts or a stub shafts. To this end, the following
conditions must be satisfied:
Ensure that the high range change group is
activated. To this end, the secondary conditions
to be satisfied are as follows:
1. Ensure current and air supply.
2. Switch the ignition ON (wait check phase).
3. No error message appears. Therefore, it is
ensured that the high range change group is
activated.
No gear is engaged in the main transmission.
Towing distance of max. 100 km.
The max. permissible towing speed depends
on the rear axle ratio and the tire dimension as
described in Fig. 4.26 on the diagram. The
respective national specifications have to be
taken into account with regard to the max.
permissible towing speed.
4-50
ZF-AS Tronic
Installation
[i Axle]
10.0
9.0
Rdyn 0.7m
8.0
7.0
6.0
5.0
4.0
3.0
2.0
10
20
25
30
35
40
50
55
v[km/h]
Fig. 4.26
Example: iAxle = 6, Rdyn = 0.5 m
Towing speed from diagram:
Vmax = 25 km/h
029023_en
NOTE
Select an operating mode in which there is no risk of
clutch overloading, for example:
Accelerate vehicle (to close the clutch).
Stop.
Set off and / or maneuver in a lower gear.
INFORMATION
It is totally forbidden to tow with a flange-mounted
propshaft or mounted stub shafts if the following
indications are present:
1) One of the conditions already described is not
satisfied.
2) An error message appears (140) or it cannot be
ensured that the high range change group and the
main transmission are switched to NEUTRAL (i.e.
vehicle breakdown undefined, failure of circuit
and/or air supply).
3) Transmission damage suspected.
DANGER!
If the driver ignores the warning, the clutch will close
when the accelerator is depressed. This prevents the
clutch from being further overloaded.
This may cause the engine to stall and rolling
backwards downhill cannot then be ruled out.
The clutch opens again when you take your foot off
the accelerator.
CAUTION
Towing the vehicle with an activated slow range
change group or an engaged gear in the main transmission rapidly leads to major transmission or
engine damage.
The operator assumes the responsibility for towing
with a flange-mounted propshaft or a stub shaft
(ensuring that all the required conditions are
satisfied).
If the vehicle is towed with a flange-mounted propshaft, prevent pollution through possible oil losses.
When towing, also observe the instructions of the
vehicle manufacturer.
4-51
ZF-AS Tronic
Installation
Stationary/Mobile operations
Depending on the type of transmission, only
certain gears will be available for stationary/
mobile PTO operation (refer to Section 3.1.7).
024406
DANGER!
The vehicle may speed up when traveling downhill.
To protect the engine from damage in the overspeed
range (red range), the system undertakes an upshift.
Stationary operations
During stationary PTO operations, no gears can be
selected. The transmission remains in Neutral.
4-52
ZF-AS Tronic
Installation
Depending on the version, a 2 or 3-digit error number will appear on the display.
This corresponds to the error currently active.
If 4 bars are displayed in addition to the number
shown, this means: Error no. + 100 (only on a twodigit display)
DANGER!
The vehicle may leave the rollers even if the
accelerator is not depressed.
024404
024405
24391
4-53
ZF-AS Tronic
Installation
4.8.2 Maintenance
4.8.2.1 Visual Inspection of Wiring
Check wiring for damage.
Check that connectors are seated correctly,
connectors must be fitted without traction relief.
NOTE
When draining the pneumatic tank, the pneumatic
cleaners and water separate should also be drained
if this is not done automatically.
If vehicles are fitted with an air dryer, the interval
for replacing the cartridge must be observed.
4-54
ZF-AS Tronic
4.9
Installation
4.9.1 Application
ZF FRIEDRICHSHAFEN AG
MADE IN GERMANY
CUSTOMER
SPEC. NO
TOTAL
RATIO
P.T.O. N
OLI CAPACIT
IN LITERS
3
4
5
SPEEDO
RATIO
n=
7
9
6
xn
ENGINE
10
023906
4.9.2 ZF Documentation
The scope of supply is defined with the customer
using the customer specification and documented in
the ZF parts list. The parts list is available as computer extract.
CAUTION
Before installation, always use the parts list number to check from the type plates whether the
engine, transmission, and electronic control unit
components correspond with the documentation.
In other words, whether they match the details on
the computer extract.
For correspondence and queries, always specify
the parts list number and serial number of your
ZF-AS Tronic (refer to type plate)!
SERIAL NO.
MODEL
4-55
ZF-AS Tronic
Installation
A10
A14
*COUNTRY:D
A90
A98
SPECIFICATION:
J32
PTO-TYPE
S02
VEHICLE DATA 1:
S04
TYPE: TRUCK
XXX
M
M
XXXXXXXXXX
S06
S08
TIRE DYN:
S10
REAR AXLE:
S14
MANUFACTURER/ENGINE *KWXXX/XXXX*N.MXXXX/XXXX
S30
DRAWINGS:
S46
CONNECTION DIAGRAM:
XXX*
I=X.XX
M
M
S48
CIRCUIT DIAGRAM:
930
932
12 AS 2331 TO
952
ECU 42 INTARDER
988
ACCESSORIES
P MN
990
PROGRAMMING
a = Customer specification
b = Type designation of vehicle manufacturer
c = Engine data
4-56
ZF-AS Tronic
Table of Contents
Annex
5.1
5-3
5.2
5.2.1
5.2.2
5.2.3
AS Transmission Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AS Transmission Program for Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AS Transmission Program for Special Vehicles . . . . . . . . . . . . . . . . . . . . . .
AS Transmission Program for Rail Vehicles . . . . . . . . . . . . . . . . . . . . . . . . .
5-4
5-4
5-5
5-5
5.3
Attached Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6
5-1
5-2
12 AS 2140 TD
12 AS 2330 TO
12
12
AS
AS
21
23
4
3
5-3
m
om
en
t li
m
it
gy
fam
ily
0
0
s
Ve
rsi
on
Va
ria
nt
Pr
od
uc
tf
am
ily
Tu
rn
ing
olo
Te
ch
n
sp
ell
ing
fg
ea
rs
of
m
be
ro
Nu
Ex
am
ple
5.1
AS
=
TC aut
= om
TC at
Tro ic t
nic ran
(A smi
S ss
+ ion
W s
Tu
SK ys
rn
) te
ing
m
0
m
=
om
Ec
e
2 ol
= ite nt [N
A
4 S 1 AS; m]
= 2 1
AS 2/ = = fa
30 142 AS cto
4 /16 10 r x
1
2; 1/
3 12 00
0
= 1;
2 =w
A
= it
S
NM ho
23
3/
V ut I
26
nt
3;
ard
er
*;
T=
1
=
Tru
Int
ck
ard
;D
er
;
=
Di
re
ct
dr
ive
;O
=
Ov
er
dr
ive
rs
ea
fg
ro
be
Nu
ZF-AS Tronic
Annex
Truck
Designation for AS transmission
Explanation
TD
TO
* Standard
019016_en
ZF-AS Tronic
5.2
Annex
AS Transmission Program
Number of gears
Torque
limits
Ratio
range
Product family
12 AS 1010 TD
12
1 000
DD
12 AS 1010 TO
12
1 000
OD
12 AS 1210 TO
12
1 200
OD
12 AS 1220 TD
12
1 200
DD
12 AS 1420 TD
12
1 400
DD
12 AS 1420 TO
12
1 400
OD
12 AS 1620 TO
12
1 600
OD
12 AS 1630 TD
12
1 700
DD
12 AS 1930 TD
12
1 900
DD
12 AS 1930 TO
12
1 900
OD
12 AS 2130 TD
12
2 100
DD
12 AS 2130 TO
12
2 100
OD
12 AS 2140 TD
12
2 100
DD
12 AS 2340 TD
12
2 300
DD
12 AS 2330 TD
12
2 300
DD
12 AS 2330 TO
12
2 300
OD
12 AS 2540 TD
12
2 500
DD
12 AS 2530 TO
12
2 500
OD
12 AS 2540 TO
12
2 500
OD
12 AS 2740 TO
12
2 700
OD
12 AS 2940 TO*
12
2 900
OD
12 AS 3140 TO*
12
3 100
OD
16 AS 2230 TD
16
2 200
DD
16 AS 2630 TO
16
2 600
OD
3
* under development
AS transmission program
No. of gears
12
16
200
2330
12 AS 1010 1220 1420 1630 1930 2130
2140 2340 2540 TD
12 AS 1010 1210 1420 1620 1930 2130 2330 2530
2540 2740 2940 3140 TO
16 AS
2230
16 AS
TD
2630
TO
400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200
under development
[Nm]
024452
5-4
ZF-AS Tronic
Annex
Designation
Number of gears
Torque
limits
Ratio
range
Transmission type
12 AS 1210 SO
12
1 200
OD
AS Tronic mid
12 AS 1620 SO
12
1 600
OD
AS Tronic mid
12 AS 2302
12
2 300
OD
AS Tronic
16 AS 2602
16
2 600
OD
AS Tronic
12 AS 2702
12
2 700
OD
AS Tronic
Designation
Number of gears
Torque
limits
Ratio
range
Transmission type
12 AS 2303
12
2 300
OD
AS Rail
16 AS 2603
16
2 600
OD
AS Rail
5-5
ZF-AS Tronic
5.3
Annex
Order no.
Type of document
Techn. information
Installation drawing
Impulse sensor
Installation drawing
Display
Installation drawing
Installation drawing
Signal switch
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Heat exchanger
Installation drawing
Installation drawing
Heat exchanger
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Rotary switch
Installation drawing
Circuit Diagram
Main computer
Circuit diagram
Wiring Diagram
Circuit diagram
Wiring Diagram
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
Installation drawing
5-6
y
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n
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/
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1
1
KL.30
2 KL.30
y
l
n
F 1 ?1 0 A
1
KL.15
KL.15
o
n
F 2 ?1 0 A
11
ADVP1
r
u
N
KL31
Computer-Zeichnung
Original
nicht verndern
Computer drawing.
Do not modify
original copy
r
o
f
n
I
r
u
z
A23
CANF-H
CANF-L
CANF-H+
CANF-L+
18
19
?
?
8
12
?
?
14
13
15
SDEF
CANF2-H
CANF2-L
ADS2
AU
EU1
12
9
15
10
Y14
Y15
Y16
Y17
A4
5V
0-5V
(-)
20 pin Kostal
3
6
A1
ADS4
Connector X1b
t
a
m
F
/
r
o
7
f
in
TCU
20 pin Kostal
n
io
SDP
connector X1a
10
SD
m
r
o
ADS1
o
i
t
a
clutch actuator
with clutch
position sensor
VM1
VM2
VMGA1
ADVP
VMHF1
VMHF2
EF
CANF1-H
CANF1-L
VMGA2
16
17
20
(-)
(-)
ground
ground
sensor ground
18
11
UE
A11
A1
U0
sensor output speed
CANF1-H+
CANF1-L+
CANF1-T
A21
VP
SDDK
VM
VM1 VM2
16
diagnosis interface
17
VM3
20
KL.31
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
28.01.98 MOLLNAU
b
08.08.07 Nal
Bearbeit. Drawn
Ind.
Anz. Nummer
Datum
Name
nderungen / Modifications
Konstr.
Design
14.01.98
NAULIN
ASTRONIC 2 MAN NT
hnl. Zeichnung
Similar Draw.
Benennung / Description
STROMLAUFPLAN
CIRCUIT DIAGRAM
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.025_B
Blatt
von
of
DIN
Sheet
Stecker/Plug
Polbildansicht
View of pin pattern
Polbild zu A1
X1A/X1B
1
3
6
15
4
7
10
11
12
POLBILD
zu A11/A14
9
8
13
3
1
14
16
17
18 19 20
DIN Baj.
4-pin
Kostal
20-pin
r
u
N
Computer-Zeichnung
Original
nicht verndern
Computer drawing.
Do not modify
original copy
r
u
z
/
n
o
i
t
a
m
r
o
f
In
A 1
A 4
ZF Getriebesteller Elektronik
Kupplungssteller mit Sensorik
A11
Drehzahlgeber Abtrieb
A21
A23
F 1
F 2
Y14
Y15
Y16
Y17
MV
MV
MV
MV
Kuppl.
Kuppl.
Kuppl.
Kuppl.
o
F
n
i
r
Anz. Nummer
Datum
Name
nderungen / Modifications
Konstr.
Design
15.01.98
NAULIN
ASTRONIC 2 MAN NT
m
r
fo
hnl. Zeichnung
Fuse 10A
Fuse 10A
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
28.01.98 MOLLNAU
b
08.08.07 Nal
Bearbeit. Drawn
Ind.
y
l
n
o
n
o
i
t
a
ZF-Kabel
ZF-Harness
sol.
sol.
sol.
sol.
valve
valve
valve
valve
clutch
clutch
clutch
clutch
engage fast
engage slow
disengage fast
disengage slow
Similar Draw.
Benennung / Description
STROMLAUFPLAN
CIRCUIT DIAGRAM
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.025_B
Blatt
von
of
DIN
Sheet
F1
1
F2
Remarks:
**pin assignment for the special design of
shift unit with 18pin connector:
KL.15
10A
shift lever
tip switch
11
12
ED2
ED3
13
ED4
14
ED5
connector X36a
CANF1-H
CANF1-L
EDM4
EDM5
14
ADM1 VPS1
r
u
N
switch
PTO 2acknowledge
S14
switch
PTO 1acknowledge
S5
r
u
z
8
o
i
t
a
E12
15
16
CANF-H+
CANF-L+
CANF-H
CANF-L
CANF-T
15
VM1
17
m
r
o
EDVP
f
In
/
n
CANF1-H+
CANF1-L+
7
9
6
8
11
?
?
?
?
?
?
o
F
18
19
8
12
14
13
15
ADVP1
SD
SDP
n
i
r
18
A23
connector X50a
relay
PTO 2
A50
ZF-extension module
EDM2
10
17
m
r
fo
11
VM1 VM2
VPE
EDM1
ADS3
ADS1
ADS4
SDEF
VMHF1
VMHF2
CANF1-H
CANF1-L
CANF1-H+
CANF1-L+
CANF1-T
connector X1b
relay
PTO 1
10
connector X50b
A5
(+) Lighting
20 pin Kostal
14
o
i
t
a
8
3
E13
E11
S4
display
optional
ADM1 VPS1
relay
reverse
light
S2
S13
7
6
8
9
11
switch
kick down
switch
PTO 2
reqest
CANF-H+
CANF-H
CANF-L
CANF-L+
CANF-T
A36
shift lever
rotary switch
ED1
EDVP
connector X1a
A45
EDM1
EDM2
EDM3
EDM4
EDM5
EDM6
EDM7
EDM8
VMG
VPE
o
n
2
3
4
5
6
7
8
9
15
2
ED1
ED2
ED3
ED4
ED5
connector X36b
10
11
12
13
14
A2
switch
PTO 1request
y
l
n
10A
KL.15
KL.31
2 KL.30
KL.30
ADS2
AU
EU1
VM2
TCU
VMGA1
Y14
Y15
Y16
Y17
CANF2-H
CANF2-L
15
10
5V
0-5V
16
17
20
(-)
(-)
ground
ground
sensor ground
**(2)
A1
3
6
(-)
VM1
details shown
on page 2
clutch actuator
with clutch
position sensor
A4
20 pin Kostal
ADVP
EF
VMGA2
18
11
UE
A11
A2
U0
VM2
18
don't supply
this circuit via
F1 or F2
Kl.30
warningbuzzer
output
speed sensor
1
VP
A21
H9
doorswitch
SDDK
diagnosis interface
16
switch
gear neutral
S12
VM1 VM2
S8
VM3
17
20
**
E17
Kl.31
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
05-04-07 Mollnau
a
07-09-12 Nal
Bearbeit. Drawn
Ind.
Anz. Nummer
Datum
Name
nderungen / Modifications
Konstr.
Design
05-04-07
Naulin
AS 2 Standard LKW
standard truck
hnl. Zeichnung
Similar Draw.
Benennung / Description
Stromlaufplan
Circuit Diagram
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.157_A
Blatt
von
of
DIN
Sheet
ZF Getriebesteller Elektronik
Fahrschalter (Tippschalter)
Fahrschalter (Drehschalter)
Kupplungssteller mit Sensorik
Display
Drehzahlgeber Abtrieb
A21
A23
A36
A50
Fahrschaltermodul
ZF-Erweiterungsmodul
F 1
F 2
H 9
E11
E12
E13
E17
Warnsummer
PTO 1 Relais
PTO 2 Relais
Rckfahrscheinwerfer
Anlassspereinrichtung
o
n
Stecker/Plug
ZF-Kabel
ZF-Harness
Polbildansicht
View of pin pattern
POLBILD
zu A36a/A50a
Polbild zu A1
X1A/X1B
POLBILD
zu A2a
POLBILD
zu A2b
POLBILD
zu A5
POLBILD
zu A21
4 7 10 13 16
3
6
4
7
JPT 3-reihig
18-pin
10
11
13
16
2 5 8 11 14
3
4 7 10 13
Abhngig von
Getriebesteller
variante
dependent by
shift unit model
Kostal
20-pin
4 7 10 13
JPT 3-reihig
15-pin
17
3 6 9 12 15
2 5 8 11 14
2 5 8
4 7
JPT 3-reihig
9-pin
JPT 3-reihig
15-pin
10
15
CAN-H
Busabschluwiderstand/
terminating
resistor
r
u
N
CAN-L
/
n
o
i
t
a
m
r
o
f
In
TCU
CAN end-user
r
u
z
8
CANF1-H
14
CANF1-H+
frei/ spare
15
CANF1-T
Fahrzeugverkabelung/
vehicle harness
13
CANF1-L+
12
CANF1-L
CAN-L
18
VMHF1
HF-ground optional
19
VMHF2
HF-ground optional
120
Ohm
HF-ground
Computer-Zeichnung
Original
nicht verndern
Computer drawing.
Do not modify
original copy
AMP M-N-L
6-pin
JPT 3-reihig
9-pin
12
16
Getriebestellerelektronik
konfiguriert
als CAN-Bus-Endteilnehmer
A23
AMP JPT
8-pin
Kostal Kuppl.
18-pin
13
17
8 5 2
9
14
18
9 6 3
7
5
3
1
POLBILD
zu A45
7 4
11
8
6
4
2
14
18 19 20
POLBILD
zu A36b/A50b
3 6 9
12
15
3 6 9 12 15
CAN-H
n
i
r
o
F
Anz. Nummer
Datum
Name
nderungen / Modifications
Konstr.
Design
Y14
Y15
Y16
Y17
MV
MV
MV
MV
sol.
sol.
sol.
sol.
Kuppl.
Kuppl.
Kuppl.
Kuppl.
Getriebestellerelektronik
konfiguriert
als CAN-Bus-Mittelteilnehmer
Naulin
valve
valve
valve
valve
clutch
clutch
clutch
clutch
engage fast
engage slow
disengage fast
disengage slow
TCU
CAN mid-user
*
A23
CAN-H
Busabschluwiderstand/
terminating
resistor
HF-ground
AS 2 Standard LKW
standard truck
CANF1-H
CAN-H
(ECU A)
14
CANF1-H+
CAN-H
(ECU B)
Fahrzeugverkabelung/
vehicle harness
120
Ohm
CAN-L
05-04-07
m
r
fo
warning buzzer
PTO 1 relay
PTO 2 relay
reverse light
starter interlock circuit
S 2
S 4
S 5
S 8
S13
S14
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
05-04-07 Mollnau
a
07-09-12 Nal
Bearbeit. Drawn
Ind.
o
i
t
a
fuse 10A
fuse 10A
3 6 9 12 15 18
2 5 8 11 14 17
y
l
n
A 1
A 2
A45
A 4
A 5
A11
15
CANF1-T
12
CANF1-L
CAN-L
13
CANF1-L+
CAN-L+ (ECU B)
18
VMHF1
HF-ground optional
19
VMHF2
HF-ground optional
hnl. Zeichnung
frei/ spare
(ECU A)
Similar Draw.
Benennung / Description
Stromlaufplan
Circuit Diagram
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.157_A
Blatt
von
of
DIN
Sheet
4
901
907
902
WX:+B/1.3
WK:K/1.3
WY:-/1.3
ZF-Erweiterungs Modul
ZF-extension module
EDVP
VPE
VPS1
VPS2
VPS3
CANF-H
CANF-H+
CANF-L
CANF-L+
EU
CANF-T
VMHF1
VMHF2
ADM1
ADM2
ADM3
VM1
VM2
900
1
901
2
503
3
4
5
-RT
6
-RT1
7
-SW
8
-SW1
9
10
11
12
13
514
14
515
15
516
16
902
17
902
18
WA:+Z/1.3
WX:+B/1.3
X80:12/2.2
A21
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
521
522
523
524
525
526
Diagnose
diagnosis
WG:RF-/1.2
X19:3/1.6
X36A:6/1.6
X19:6/1.6
X36A:8/1.6
LX21
A5
LX36
X50A
X80:13/2.2
X80:14/2.2
X80:15/2.2
WY:-/1.3
WE:-/1.3
X5
X80:11/2.2
901
X19:5/1.6
X80:5/2.2
WU
X19:8/1.6
X18:1/2.2
WR
X19:13/1.6
X18:3/2.2
WS
CH
CL
X19:17/1.6
X18:2/2.2
WP
948
917
906
920
921
CH+
X19:18/1.6
X18:4/2.2
WQ
CL+
X5:3/1.5
X80:4/2.2
WZ
X5:4/1.5
X19:9/1.6
WT
+Bel
907
902
902
SD
X5:8/1.5
X19:15/1.6
WJ
+A
X36A:3/1.6
X80:8/2.2
WF
X36A:14/1.6
X80:9/2.2
WG
Computer-Zeichnung
Original
nicht verndern
Computer drawing.
Do not modify
original copy
r
u
z
922
RF+
X50A:2/1.1
X36A:2/1.6
X19:4/1.6
X21:1/1.3
X80:2/2.2
948
917
WE:-/1.3
902
WJ:+A/1.2
906
m
r
o
X80:1/2.2
X19:2/1.6
X50A:1/1.1
X36A:1/1.6
X19:7/1.6
X80:3/2.2
X21:2/1.3
X19:1/1.6
X80:6/2.2
X50A:17/1.1
X36A:18/1.6
X19:12/1.6
X21:3/1.3
X80:22/2.2
X80:21/2.2
X19:16/1.6
X50A:18/1.1
X5:6/1.5
X36A:17/1.6
WC
+B
WA
/
n
o
i
t
a
+B
1
2
3
4
5
6
7
8
+Bel.
SD
LX80
n
i
r
VM
VP
o
F
WK:K/1.3
WC:+B/1.3
X50A:6/1.1
WX:+B/1.3
WU:EF/1.2
X50A:8/1.1
WA:+Z/1.3
WR:CH/1.2
WT:SD/1.2
X19
WY:-/1.3
WS:CL/1.2
WJ:+A/1.2
WE:-/1.3
WP:CH+/1.2
WQ:CL+/1.2
X80/2.1
+Z
907
901
-RT
901
918
-SW
900
-GE1
917
1
2
3
4
5
6
7
8
9
10
11
902
12
-GN1
13
14
906
15
902
16
-GE2
17
-GN2
18
X19
AU
EDM1
EDM2
EDM3
EDM4
EDM5
CANF-L
CANF-L+
CANF-T
ED1
ED2
ED3
ED4
ED5
VMG
ADM1
VM1
VM2
Name
nderungen / Modifications
RC
R
N
D
DC
o
i
t
a
Fahrschalter Modul
shift lever module
907
901
-RT
901
918
-SW
900
-GE1
917
X1:2/1.8
X1:4/1.8
X1:3/1.8
X1:5/1.8
X1:7/1.8
X1:6/1.8
X1:1/1.8
X1:8/1.8
X1:9/1.8
905
902
-GN1
919
906
902
-GE2
-GN2
X1
X20
X1:18/1.8
X1:16/1.8
X1:12/1.8
X1:10/1.8
X1:11/1.8
X1:17/1.8
X1:14/1.8
X1:13/1.8
WK
WY
Polbild
zu X19
Polbild
zu X20
2 5 8 11 14 17
1
WE
4 7 10 13 16
JPT 3-reihig
18-pin
LX18
X18/2.1
POLBILD
zu X36B/X50B
18
16
14
12
10
8
6
4
2
17 18
15 16
13 14
11 12
9 10
7 8
5 6
3 4
1 2
POLBILD
zu X21
12
11
13
14
16
17
18 19 20
AMP JPT
18-pin
3 6 9 12 15
Abhngig von
Getriebesteller
Variante
dependent by
shift unit model
Kostal
20-pin
17
15
13
11
9
7
5
3
1
3
7
11
AMP JPT
18-pin
A1
VPI
SDDK
CANF2-H
VPE1
VPE2
CANF2-L
SDEF
CANF1-H
SD
SDP
ADVP
CANF1-L
CANF-1L+
CANF1-H+
CANF1-T
VM1
VM2
VMHF1
VMHF2
VM3
15
900
1
907
2
-RT
3
901
4
901
5
-SW
6
918
7
-GE1
8
917
9
919
10
906
11
-GN1
12
-GN2
13
-GE2
14
15
902
16
902
17
905
18
19
20
X1
3 6 9 12 15 18
X20:7/1.7
X20:1/1.7
X20:3/1.7
X20:2/1.7
X20:4/1.7
X20:6/1.7
X20:5/1.7
X20:8/1.7
X20:9/1.7
X20:14/1.7
X20:15/1.7
X20:13/1.7
X20:18/1.7
X20:17/1.7
Polbild
zu X1
POLBILD
zu X36A/X50A
Fahrschalter
shift lever
X20:12/1.7
X20:16/1.7
X20:11/1.7
T+
TT 0-pos.
A/M
A/M 0-pos.
ZF Getriebesteller Elektronik
TCU transmission control unit
LX 1
X20
y
l
n
o
n
X36B
2
5
14
13
17
AMP M-N-L
6-pin
POLBILD
zu X5
4
9
18
6
10
15
8
6
4
2
12
16
2 5 8 11 14
H<1
X80:7/2.2
WH
4 7 10 13
FSN
Kostal Kuppl.
18-pin
JPT 3-reihig
15-pin
Datum
A2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
10
RF-
Anz. Nummer
CANF-H
A36
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
17.01.06 MOLLNAU
a
12.09.07 Nal
Bearbeit. Drawn
Ind.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
EDVP
VPE
VPS1
m
r
fo
X36A
X5
LX19
WX
f
In
EF
r
u
N
-GN2
WZ:+Bel/1.2
WT:SD/1.2
LX5
X80:10/2.2
X80:16/2.2
X80:17/2.2
X80:18/2.2
X80:19/2.2
X80:20/2.2
900
-GE2
WE:-/1.3
WY:-/1.3
Display
display
X50B
-GN1
1
2
3
4
5
-RT1
6
7
-SW1
8
950
9
10
950
11
12
13
921
14
15
16
902
17
902
18
X36A:9/1.6
901
-GE1
900
901
920
X50A:9/1.1
X36A:11/1.6
X36
X21
X50B
918
X50A:7/1.1
KN1
535
6
WA:+Z/1.3
WX:+B/1.3
WF:RF+/1.2
X50A
A50
ADVP
EDM1
EDM2
EDM3
EDM4
EDM5
EDM6
EDM7
EDM8
ED1
ED2
ED3
ED4
ED5
VMG
X21
1 (+)
2 K
3 (-)
4 L
5 Pog
6
Konstr.
Design
17.01.06
MOLLNAU
AS 2 Standard LKW
standard truck
hnl. Zeichnung
AMP JPT
8-pin
Similar Draw.
Benennung / Description
ANSCHLUSSPLAN
CONNECTION DIAG.
7
5
3
1
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.158_A
Blatt
von
of
DIN
Sheet
POLBILD
zu X80
22 21
20 19
18 17
16 15
14 13
12 11
10 9
8 7
6 5
4 3
2 1
21 22
19 20
17 18
15 16
13 14
11 12
9 10
7 8
5 6
3 4
1 2
X80/1.5
"X17/BN"
901
901
900
948
918
907
922
920
921
521
535
503
514
515
516
522
523
524
525
526
902
902
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
F1
X18/1.5
r
u
N
"X18/CAN"
vehicle electr.circuit(+30)
vehicle electr.circuit(+30)
vehicle electr.circuit(+15)
(+) lighting display
signal output speed
K-Line
->
->
->
->
RCKLICHT +
RCKLICHT ADVP
WARNSUMMER
VPS1
-> RELAIS PTO 1
-> RELAIS PTO 2
reverse light +
reverse light(-)
ADVP
warning buzzer
VPS1
relay PTO 1
relay PTO 2
<<<<<<<-
request PTO 1
request PTO 2
switch acknowledge PTO 1
switch acknowledge PTO 2
door switch
vehicle electr.circuit(-)
vehicle electr.circuit(-)
PTO 1 ANFORDERUNG
PTO 2 ANFORDERUNG
PTO 1 RCKMELDUNG
PTO 2 RCKMELDUNG
TRSCHALTER
BORDNETZ(Kl.31)
BORDNETZ(Kl.31)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
X18
f
In
Anz. Nummer
o
n
Sensor
output speed
D3orB7
/
n
o
F
n
i
r
S8
m
r
fo
E12
S5
S14
E11
S4
E13
H9
S13
A23
1
2
3
4
5
6
POLBILD
zu X18A
6 5
4 3
2 1
Datum
y
l
n
o
i
t
a
A14
Tachograph
5
3
1
X18A
A23
6
4
2
AMP JPT
6-pin
Kl.31
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
17.01.06 MOLLNAU
a
12.09.07 Nal
Bearbeit. Drawn
Ind.
10A
optional
o
i
t
a
CAN
vehicle interface
CANF1-H
CANF1-H+
CANF1-L
CANF1-L+
VMHF-1
VMHF-2
POLBILD
zu X18
F2
A13
m
r
o
AMP JPT
6-pin
Computer-Zeichnung
Original
nicht verndern
Computer drawing.
Do not modify
original copy
10A
X80A
1
2
3
4
5
6
Kl.15
<- BORDNETZ(Kl.30)
<- BORDNETZ(Kl.30)
<- BORDNETZ(Kl.15)
<- (+) BEL. DISPLAY
<- ABTRIEBSDREHZAHL
<-> K-LEITUNG
r
u
z
-GE1
-GE2
-GN1
-GN2
Kl.30
X80
WR:CH/1.2
WP:CH+/1.2
WS:CL/1.2
WQ:CL+/1.2
AMP JPT
22-pin
AMP JPT
22-pin
WC:+B/1.3
WX:+B/1.3
WA:+Z/1.3
WZ:+Bel/1.2
WU:EF/1.2
WK:K/1.3
WH:FSN/1.3
WF:RF+/1.2
WG:RF-/1.2
X50B:1/1.1
X50B:15/1.1
X50A:3/1.1
X50A:14/1.1
X50A:15/1.1
X50A:16/1.1
X50B:2/1.1
X50B:3/1.1
X50B:4/1.1
X50B:5/1.1
X50B:6/1.1
WE:-/1.3
WY:-/1.3
POLBILD
zu X80A
Name
nderungen / Modifications
Konstr.
Design
17.01.06
MOLLNAU
AS 2 Standard LKW
standard truck
hnl. Zeichnung
Similar Draw.
Benennung / Description
ANSCHLUSSPLAN
CONNECTION DIAG.
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.158_A
Blatt
von
of
DIN
Sheet
F1
1
10A
2
F2
relay
shift lever
neutral
E41
A2
shift lever
relay
reverse
light
CANF-H+
CANF-H
CANF-L
CANF-L+
CANF-Ra
CANF-Rb
AD1 VM3
9
12
4
3
1
2
14
15
A5
A23
CANF1-H
CANF1-L
10
11
ED1
12
ED2
ED3
13
ED4
14
15
ADM1 VPS1
16
r
u
z
connector X50b
EDM4
EDM5
EDM6
EDM7
S4
CANF-H+
CANF-L+
CANF-H
CANF-L
CANF-T
f
In
A50
ZF-extension module
r
u
N
switch
PTO 2acknowledge
S14
switch
PTO 1acknowledge
S5
15
VM1
17
m
r
o
EDVP
EDM3
S13
VPE
EDM2
switch
PTO 2
reqest
connector X50a
EDM1
o
i
t
a
E12
14
ED5
/
n
CANF1-H+
CANF1-L+
relay
PTO 2
7
9
6
8
11
?
?
o
F
8
12
14
13
15
SDP
ADS3
ADS1
ADS4
SDEF
VMHF1
VMHF2
CANF1-H
CANF1-L
CANF1-H+
CANF1-L+
CANF1-T
ADS2
AU
EU1
Y14
Y15
Y16
Y17
VM2
TCU
VMGA1
A1
CANF2-H
CANF2-L
15
10
5V
0-5V
(-)
VM1
3
6
A4
details shown
on page 2
clutch actuator
with clutch
position sensor
16
17
20
(-)
(-)
ground
ground
sensor ground
**(2)
ADVP
EF
VMGA2
18
11
UE
A11
A2
U0
VM2
output
speed sensor
18
Kl.30
1
VP
warningbuzzer
A21
H9
doorswitch
?
?
18
19
ADVP1
SD
n
i
r
VM2
8
relay
starter interlock
E11
9
10
?
?
m
r
fo
11
optional
E13
E17
4
6
S12
relay
PTO 1
(+) Lighting
connector X1b
VPE EDVP
20 pin Kostal
e41
7
15 pin AMP J.P.T
ADM
EDM
EDM
EDM
EDM
EDM
VM
EDM
don't supply
this circuit via
F1 or F2
1
3
5
2
4
6
7
connector X2b
1
3
5
2
4
6
7
connector X1a
13
RM
R
N
D
DM
VM
N_DS
o
i
t
a
display
connector X2a
shift lever
rotary switch
switch
PTO 1request
o
n
10A
A45
y
l
n
Remarks:
**pin assignment for the special design of
shift unit with 18pin connector:
KL.15
KL.15
KL.31
2 KL.30
KL.30
20 pin Kostal
SDDK
VM1 VM2
3
diagnosis interface
S8
16
VM3
17
20
**
Kl.31
Computer-Zeichnung
Original
nicht verndern
Computer drawing.
Do not modify
original copy
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
06-06-20 Mollnau
a
07-09-12 Nal
Bearbeit. Drawn
Ind.
Anz. Nummer
Datum
Name
nderungen / Modifications
Konstr.
Design
05-04-07
Naulin
AS 2 Standard LKW
standard truck
hnl. Zeichnung
Similar Draw.
Benennung / Description
Stromlaufplan
Circuit Diagram
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.163_A
Blatt
von
of
DIN
Sheet
ZF Getriebesteller Elektronik
Fahrschalter
Fahrschalter (Drehschalter)
Kupplungssteller mit Sensorik
Display
Drehzahlgeber Abtrieb
A21
A23
A50
F 1
F 2
H 9
E11
E12
E13
E17
E41
Warnsummer
PTO 1 Relais
PTO 2 Relais
Rckfahrscheinwerfer
Anlasssperrrelais
Relais Fahrschalter Neutral
warning buzzer
PTO 1 relay
PTO 2 relay
reverse light
starter interlock
relay shift lever neutral
S 2
S 4
S 5
S 8
S12
S13
S14
Y14
Y15
Y16
Y17
MV
MV
MV
MV
sol.
sol.
sol.
sol.
o
n
Stecker/Plug
ZF-Kabel
ZF-Harness
Polbildansicht
View of pin pattern
POLBILD
zu A50a
Polbild zu A1
X1A/X1B
POLBILD
zu A2a
POLBILD
zu A2b
POLBILD
zu A5
POLBILD
zu A21
4 7 10 13 16
3
6
4
7
JPT 3-reihig
18-pin
10
11
13
16
2 5 8 11 14
3
4 7 10 13
Abhngig von
Getriebesteller
variante
dependent by
shift unit model
Kostal
20-pin
4 7 10 13
JPT 3-reihig
15-pin
17
3 6 9 12 15
2 5 8 11 14
2 5 8
4 7
JPT 3-reihig
9-pin
JPT 3-reihig
15-pin
15
14
CAN-H
Busabschluwiderstand/
terminating
resistor
r
u
N
CAN-L
/
n
o
i
t
a
m
r
o
f
In
TCU
CAN end-user
r
u
z
8
CANF1-H
14
CANF1-H+
frei/ spare
15
CANF1-T
Fahrzeugverkabelung/
vehicle harness
13
CANF1-L+
12
CANF1-L
CAN-L
18
VMHF1
HF-ground optional
19
VMHF2
HF-ground optional
120
Ohm
HF-ground
Computer-Zeichnung
Original
nicht verndern
Computer drawing.
Do not modify
original copy
AMP M-N-L
6-pin
JPT 3-reihig
9-pin
12
16
Getriebestellerelektronik
konfiguriert
als CAN-Bus-Endteilnehmer
A23
AMP JPT
8-pin
Kostal Kuppl.
18-pin
13
17
8 5 2
18
9 6 3
10
7
5
3
1
POLBILD
zu A45
7 4
11
8
6
4
2
14
18 19 20
POLBILD
zu A50b
3 6 9
12
15
3 6 9 12 15
CAN-H
n
i
r
o
F
Kuppl.
Kuppl.
Kuppl.
Kuppl.
Anz. Nummer
Datum
Name
nderungen / Modifications
Konstr.
Design
Getriebestellerelektronik
konfiguriert
als CAN-Bus-Mittelteilnehmer
Naulin
valve
valve
valve
valve
clutch
clutch
clutch
clutch
engage fast
engage slow
disengage fast
disengage slow
TCU
CAN mid-user
*
A23
CAN-H
Busabschluwiderstand/
terminating
resistor
HF-ground
AS 2 Standard LKW
standard truck
CANF1-H
CAN-H
(ECU A)
14
CANF1-H+
CAN-H
(ECU B)
Fahrzeugverkabelung/
vehicle harness
120
Ohm
CAN-L
05-04-07
m
r
fo
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
06-06-20 Mollnau
a
07-09-12 Nal
Bearbeit. Drawn
Ind.
o
i
t
a
fuse 10A
fuse 10A
3 6 9 12 15 18
2 5 8 11 14 17
y
l
n
A 1
A 2
A45
A 4
A 5
A11
15
CANF1-T
12
CANF1-L
CAN-L
13
CANF1-L+
CAN-L+ (ECU B)
18
VMHF1
HF-ground optional
19
VMHF2
HF-ground optional
hnl. Zeichnung
frei/ spare
(ECU A)
Similar Draw.
Benennung / Description
Stromlaufplan
Circuit Diagram
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.163_A
Blatt
von
of
DIN
Sheet
4
901
907
902
WX:+B/1.3
WK:K/1.3
WY:-/1.3
ZF-Erweiterungs Modul
ZF-extension module
EDVP
VPE
VPS1
VPS2
VPS3
CANF-H
CANF-H+
CANF-L
CANF-L+
EU
CANF-T
VMHF1
VMHF2
ADM1
ADM2
ADM3
VM1
VM2
900
1
901
2
503
3
4
5
-RT
6
-RT1
7
-SW
8
-SW1
9
10
11
12
13
514
14
515
15
516
16
902
17
902
18
WA:+Z/1.3
WX:+B/1.3
X80:12/2.2
X21
X19:3/1.6
X2A:3/1.6
X19:6/1.6
X2A:1/1.6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
521
522
523
524
525
526
Diagnose
diagnosis
X50A:7/1.1
X2
A21
WG:RF-/1.2
WH:FSN/1.3
X2A:15/1.6
X2A:14/1.6
X50A
X80:13/2.2
X80:14/2.2
X80:15/2.2
WY:-/1.3
WE:-/1.3
X5
WZ:+Bel/1.2
WT:SD/1.2
948
917
WE:-/1.3
902
WJ:+A/1.2
906
LX5
X80:10/2.2
X80:16/2.2
X80:17/2.2
X80:18/2.2
X80:19/2.2
X80:20/2.2
LX50
X80:11/2.2
901
-GN1
-GE2
WU
X19:8/1.6
X82:1/2.2
WR
X19:13/1.6
X82:3/2.2
WS
X19:17/1.6
X82:2/2.2
EF
CH
CL
WP
r
u
N
-GN2
948
917
906
920
921
X19:18/1.6
X82:4/2.2
X5:3/1.5
X80:4/2.2
X5:4/1.5
X19:9/1.6
X5:8/1.5
X19:15/1.6
CH+
WQ
CL+
WZ
+Bel
WT
907
902
902
SD
WJ
X21:2/1.3
X19:1/1.6
X80:6/2.2
X50A:17/1.1
X2A:8/1.6
X19:12/1.6
X21:3/1.3
X80:22/2.2
X80:21/2.2
X19:16/1.6
X50A:18/1.1
X5:6/1.5
+B
WA
LX80
WF
X2A:12/1.6
X80:9/2.2
WG
922
RF+
1
2
-RT1
3
4
5
901
6
900
7
902
8
920
9
10
11
921
12
922
13
950
14
950
15
Display
o
F
WK:K/1.3
WC:+B/1.3
X50A:6/1.1
WX:+B/1.3
WU:EF/1.2
X50A:8/1.1
WA:+Z/1.3
WR:CH/1.2
WT:SD/1.2
X19
WY:-/1.3
WS:CL/1.2
WJ:+A/1.2
WE:-/1.3
WP:CH+/1.2
WQ:CL+/1.2
X80/2.1
+Z
RC
D
R
DC
N
VM
N_DS
VM3
401
402
403
404
405
406
407
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11
902
12
-GN1
13
14
906
15
902
16
-GE2
17
-GN2
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
907
901
-RT
901
918
-SW
900
-GE1
917
X1:2/1.8
X1:4/1.8
X1:3/1.8
X1:5/1.8
X1:7/1.8
X1:6/1.8
X1:1/1.8
X1:8/1.8
X1:9/1.8
905
902
-GN1
919
906
902
-GE2
-GN2
Name
nderungen / Modifications
Konstr.
X1
X1:18/1.8
X1:16/1.8
X1:12/1.8
X1:10/1.8
X1:11/1.8
X1:17/1.8
X1:14/1.8
X1:13/1.8
Polbild
zu X1
1
WY
Polbild
zu X20
15
2 5 8 11 14 17
1
WE
4 7 10 13 16
JPT 3-reihig
18-pin
LX82
X82/2.1
POLBILD
zu X50B
18
16
14
12
10
8
6
4
2
17 18
15 16
13 14
11 12
9 10
7 8
5 6
3 4
1 2
11
13
AMP JPT
18-pin
11
AMP JPT
18-pin
2
5
14
13
Abhngig von
Getriebesteller
Variante
dependent by
shift unit model
4
18
17
4 7 10 13
JPT 3-reihig
15-pin
8
12
16
FSN
4 7 10 13
Kostal Kuppl.
18-pin
AS 2 Standard LKW
standard truck
ANSCHLUSSPLAN
CONNECTION DIAG.
8
6
4
2
4 7
7
5
3
1
AMP JPT
8-pin
JPT 3-reihig
9-pin
Similar Draw.
Benennung / Description
POLBILD
zu X5
3 6 9
2 5 8
MOLLNAU
AMP M-N-L
6-pin
POLBILD
zu X2B
17.01.06
POLBILD
zu X21
2 5 8 11 14
2 5 8 11 14
Design
A1
3 6 9 12 15
WH
hnl. Zeichnung
VPI
SDDK
CANF2-H
VPE1
VPE2
CANF2-L
SDEF
CANF1-H
SD
SDP
ADVP
CANF1-L
CANF1-L+
CANF1-H+
CANF1-T
VM1
VM2
VMHF1
VMHF2
VM3
6
10
15
900
1
907
2
-RT
3
901
4
901
5
-SW
6
918
7
-GE1
8
917
9
919
10
906
11
-GN1
12
-GN2
13
-GE2
14
15
902
16
902
17
905
18
19
20
POLBILD
zu X2A
14
16
17
18 19 20
A45
Fahrschalter (Drehschalter)
shift lever (rotary switch)
9
8
12
Kostal
20-pin
17
15
13
11
9
7
5
3
1
X45
3 6 9 12 15 18
RC
D
R
DC
N
VM
N_DS
X1
2
4
Polbild
zu X19
X20:7/1.7
X20:1/1.7
X20:3/1.7
X20:2/1.7
X20:4/1.7
X20:6/1.7
X20:5/1.7
X20:8/1.7
X20:9/1.7
X20:14/1.7
X20:15/1.7
X20:13/1.7
X20:18/1.7
X20:17/1.7
X20:12/1.7
X20:16/1.7
X20:11/1.7
WK
y
l
n
o
n
X45
1
2
3
4
5
6
7
8
9
X20
X20
401
402
403
404
405
406
407
X2B:1/1.7
X2B:2/1.7
X2B:3/1.7
X2B:4/1.7
X2B:5/1.7
X2B:6/1.7
X2B:7/1.7
ZF Getriebesteller Elektronik
LX 1
10
POLBILD
zu X50A
o
i
t
a
X2B
m
r
fo
JPT 3-reihig
15-pin
Datum
X45:1/1.8
X45:2/1.8
X45:3/1.8
X45:4/1.8
X45:5/1.8
X45:6/1.8
X45:7/1.8
X2B
CANF-Ra
CANF-Rb
X19
RF-
Anz. Nummer
A2
907
901
-RT
901
918
-SW
900
-GE1
917
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
20.06.06 MOLLNAU
a
12.09.07 Nal
Bearbeit. Drawn
Ind.
VPE
EDVP
VM2
AD1
n
i
r
VP
3 6 9 12 15
X2A:13/1.6
X80:7/2.2
CANF-L
CANF-L+
CANF-H
CANF-H+
Fahrschalter
shift lever
VM
+A
X2A:9/1.6
X80:8/2.2
Computer-Zeichnung
Original
nicht verndern
Computer drawing.
Do not modify
original copy
r
u
z
m
r
o
WC
/
n
o
i
t
a
+B
X80:1/2.2
X19:2/1.6
X50A:1/1.1
X2A:7/1.6
X19:7/1.6
X80:3/2.2
LX19
WX
f
In
900
X19:5/1.6
X80:5/2.2
X50A:2/1.1
X2A:6/1.6
X19:4/1.6
X21:1/1.3
X80:2/2.2
KN1
-SW1
+Bel.
SD
X5
X50B
-GE1
1
2
3
4
5
6
7
8
LX 2
X2A
A5
901
918
WX:+B/1.3
WA:+Z/1.3
WY:-/1.3
WF:RF+/1.2
LX21
X50B
535
6
X50A:9/1.1
1 (+)
2 K
3 (-)
4 L
5 Pog
6
X50A
A50
ADVP
EDM1
EDM2
EDM3
EDM4
EDM5
EDM6
EDM7
EDM8
ED1
ED2
ED3
ED4
ED5
VMG
X21
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.166_A
Blatt
von
of
DIN
Sheet
POLBILD
zu X80
22 21
20 19
18 17
16 15
14 13
12 11
10 9
8 7
6 5
4 3
2 1
21 22
19 20
17 18
15 16
13 14
11 12
9 10
7 8
5 6
3 4
1 2
X80/1.5
"X17/BN"
901
901
900
948
918
907
922
920
921
521
535
503
514
515
516
522
523
524
525
526
902
902
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
<- BORDNETZ(Kl.30)
<- BORDNETZ(Kl.30)
<- BORDNETZ(Kl.15)
<- (+) BEL. DISPLAY
<- ABTRIEBSDREHZAHL
<-> K-LEITUNG
-> Fahrsch. Neutral
-> RCKLICHT +
-> RCKLICHT -> ADVP
-> WARNSUMMER
VPS1
-> RELAIS PTO 1
-> RELAIS PTO 2
<<<<<<<-
F1
X82/1.5
r
u
N
"X82/CAN"
PTO 1 ANFORDERUNG
PTO 2 ANFORDERUNG
PTO 1 RCKMELDUNG
PTO 2 RCKMELDUNG
TRSCHALTER
BORDNETZ(Kl.31)
BORDNETZ(Kl.31)
request PTO 1
request PTO 2
switch acknowledge PTO 1
switch acknowledge PTO 2
door switch
vehicle electr.circuit(-)
vehicle electr.circuit(-)
CANF1-H
CANF1-H+
CANF1-L
CANF1-L+
VMHF-1
VMHF-2
POLBILD
zu X18
Anz. Nummer
POLBILD
zu X18A
6 5
4 3
2 1
Datum
y
l
n
o
n
10A
A13
E41
optional
o
i
t
a
A14
Sensor
output speed
Tachograph
D3orB7
/
n
m
r
o
o
F
n
i
r
S8
m
r
fo
E12
S5
S14
E11
S4
E13
H9
S13
A23
5
3
1
X18A
A23
6
4
2
AMP JPT
6-pin
Kl.31
Diese Zeichnung darf weder kopiert, noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Diese Konstruktion ist unser Eigentum.
This drawing may not be copied or disclosed to third persons without permission of ZF. We are the owner of this design.
Techn. Information
Technical Information
20.06.06 MOLLNAU
a
12.09.07 Nal
Bearbeit. Drawn
Ind.
1
2
3
4
5
6
AMP JPT
6-pin
Computer-Zeichnung
Original
nicht verndern
Computer drawing.
Do not modify
original copy
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
o
i
t
a
f
In
r
u
z
X82
F2
10A
X80A
1
2
3
4
5
6
Kl.15
vehicle electr.circuit(+30)
vehicle electr.circuit(+30)
vehicle electr.circuit(+15)
(+) lighting display
signal output speed
K-Line
shift lever neutral
reverse light +
reverse light ADVP
warning buzzer
VPS1
relay PTO 1
relay PTO 2
CAN
vehicle interface
-GE1
-GE2
-GN1
-GN2
Kl.30
X80
WR:CH/1.2
WP:CH+/1.2
WS:CL/1.2
WQ:CL+/1.2
AMP JPT
22-pin
AMP JPT
22-pin
WC:+B/1.3
WX:+B/1.3
WA:+Z/1.3
WZ:+Bel/1.2
WU:EF/1.2
WK:K/1.3
WH:FSN/1.3
WF:RF+/1.2
WG:RF-/1.2
X50B:1/1.1
X50B:15/1.1
X50A:3/1.1
X50A:14/1.1
X50A:15/1.1
X50A:16/1.1
X50B:2/1.1
X50B:3/1.1
X50B:4/1.1
X50B:5/1.1
X50B:6/1.1
WE:-/1.3
WY:-/1.3
POLBILD
zu X80A
Name
nderungen / Modifications
Konstr.
Design
17.01.06
MOLLNAU
AS 2 Standard LKW
standard truck
hnl. Zeichnung
Similar Draw.
Benennung / Description
ANSCHLUSSPLAN
CONNECTION DIAG.
ZF Friedrichshafen AG
Zeichnungs-Nr. Drawing-No.
Ind.
6029.713.166_A
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ZF Friedrichshafen AG
Hauptverwaltung
88038 Friedrichshafen
Telefon +49 7541 77-0
Telefax +49 7541 77-908000
www.zf.com